Process of making polymer blends

ABSTRACT

In a process for producing a polymer blend, at least one first monomer is polymerized in a first slurry phase reaction zone in the presence of a supported first catalyst comprising a Ziegler-Natta component to produce a thermoplastic first polymer having a crystallinity of at least 30%. At least part of said first polymer is then contacted with at least one second monomer different from said first monomer and at least one polyene in a second solution phase reaction zone in the presence of a second catalyst under conditions to produce and at least partially cross-link said second polymer such that said second polymer comprises at least a fraction which is insoluble in xylene and has a crystallinity of less than 20%.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 11/454,950, filed on Jun. 16, 2006 and U.S. patent application Ser. No. 11/296,830, filed on Dec. 7, 2005.

FIELD OF THE INVENTION

This invention relates to a process of making polymer blends.

BACKGROUND OF THE INVENTION

Polymer blends comprising a second polymer dispersed in a matrix of a first polymer are very useful and, depending on the properties and the relative amounts of the first and second polymers, a wide variety of such polymer blends can be produced. Of particular interest are polymer blends, also referred to as thermoplastic elastomers (TPE).

One method of making the aforementioned polymer blends is by melt mixing the two different polymers after they have been polymerized to achieve a target set of properties. Examples of such processes employing vanadium catalysts in series reactor operation to produce different types of EPDM compositions are disclosed in U.S. Pat. Nos. 3,629,212; 4,016,342; and 4,306,041.

U.S. Pat. No. 6,245,856 discloses a thermoplastic olefin composition comprising polypropylene, an ethylene-alpha olefin elastomer and a compatabilizer comprising an ethylene-propylene copolymer having a propylene content of greater than 80 weight percent. In the absence of the compatabilizer, the elastomer phase is said to be uneven with particles greater than 5 microns in size, whereas the addition of the compatabilizer is said to improve dispersion such that the elastomer phase has a particle size of about 1 micron. The elastomer phase of this polymer blend is not cross-linked.

U.S. Pat. No. 6,207,756 describes a process for producing a blend of a continuous phase of a semi-crystalline plastic, such as polypropylene, and a discontinuous phase of an amorphous elastomer, such as a terpolymer of ethylene, a C₃-C₂₀ alpha olefin and a non-conjugated diene. U.S. Pat. No. 6,319,998 also discloses using series solution polymerizations to produce blends of ethylene copolymers. U.S. Pat. No. 6,770,714 discloses the use of parallel polymerizations to produce different polymeric components that are then blended through extrusion or using other conventional mixing equipment.

One problem involved in producing thermoplastic elastomeric blends by direct polymerization, particularly blends having a high molecular weight and high melting temperature crystalline phase and a high molecular weight elastomeric phase, is the disparate conditions favoring the production of the individual blend components. Thus, for example, isotactic polypropylene is widely produced commercially by a slurry polymerization process, whereas ethylene propylene copolymer with desired properties for TPE applications is commercially produced in a solution process. However, the solution process is not currently capable of producing polypropylene with high molecular weight and high melting point. Ethylene propylene copolymer elastomers have been difficult to produce using slurry-based polymerization systems since, even at low reactor temperatures, these tend to result in reactor fouling and the formation of rubbery clumps that attach themselves to the reactor agitator, thereby necessitating reactor shut-down. It is therefore difficult, if not impossible, to produce TPE material in reactor using either a slurry process (good for polypropylene) or a solution process (good for rubber).

In addition to the issue of reaction conditions, choice of polymerization catalyst is another factor that currently limits in-reactor blending of TPE materials. There is a general perception in the industry that Ziegler-Natta catalysts and metallocene catalysts are incompatible and hence there is currently no in-reactor process for producing blends of Ziegler-Natta-produced polypropylene with metallocene-produced elastomer.

One particularly useful form of thermoplastic elastomer is a thermoplastic vulcanizate (“TPV”). TPVs are normally produced by a process of “dynamic vulcanization”. Examples of dynamic vulcanization are described in the U.S. Pat. Nos. 4,130,535 and 4,311,628.

An improved process for producing TPVs is disclosed in U.S. Pat. No. 6,388,016, incorporated herein in its entirety, in which a polymer blend is produced by solution polymerization in series reactors employing metallocene catalysts and the resultant blend is subjected to dynamic vulcanization. It will, however, be seen that this improved process still relies on dynamic vulcanization to cure the elastomeric component. Moreover, there is a limit to the molecular weight of the polymers that can be produced, due to the resulting increase in solution viscosity, phase-separation of produced polymer and reactor fouling at low reaction temperature inherent in the use of solution polymerization to produce the elastomeric second polymer.

There is therefore a need for an improved, in-reactor process for producing polymer blends and, in particular, polymer blends comprising a thermoplastic continuous phase and a cross-linked elastomeric phase dispersed in the continuous phase.

U.S. Pat. No. 6,492,473 describes a mixed transition metal olefin polymerization catalyst system suitable for the polymerization of olefin monomers comprising at least one late transition metal catalyst system and at least one different catalyst system selected from the group consisting of late transition metal catalyst systems, transition metal metallocene catalyst systems or Ziegler-Natta catalyst systems. Preferred embodiments include at least one late transition metal catalyst system comprising a Group 9, 10, or 11 metal complex stabilized by a bidentate ligand structure and at least one transition metal metallocene catalyst system comprising a Group 4 metal complex stabilized by at least one ancillary cyclopentadienyl ligand. The polymerization process for olefin monomers comprises contacting one or more olefins with these catalyst systems under polymerization conditions.

SUMMARY OF THE INVENTION

In one aspect, the present invention resides in a process for producing a polymer blend comprising a thermoplastic first polymer having a crystallinity of at least 30% and a second polymer having a crystallinity of less than 20% and being at least partially cross-linked, the process comprising:

(a) polymerizing at least one first monomer in a first slurry phase reaction zone in the presence of a supported first catalyst under conditions to produce said thermoplastic first polymer, said first catalyst comprising a Ziegler-Natta catalyst; and

(b) contacting at least part of said first polymer with at least one second monomer different from said first monomer and at least one polyene in a second solution phase reaction zone under conditions sufficient to polymerize said second monomer to produce and at least partially cross-link said second polymer such that said second polymer comprises at least a fraction which is insoluble in xylene.

DESCRIPTION OF THE DRAWING

FIG. 1 is an atomic force micrograph (AFM) of the polymer blend produced in Example 1-1 (image size=20×20 μm).

DETAILED DESCRIPTION OF THE EMBODIMENTS

As used herein, the numbering scheme for the Periodic Table Groups is the new notation as set out in CHEMICAL AND ENGINEERING NEWS, 63(5), 27 (1985).

For purposes of this invention and the claims thereto when a polymer or oligomer is referred to as comprising an olefin, the olefin present in the polymer or oligomer is the polymerized or oligomerized form of the olefin, respectively. Likewise the use of the term polymer is meant to encompass homopolymers and copolymers. In addition the term copolymer includes any polymer having 2 or more monomers. Thus, as used herein, the term “polypropylene” means a polymer made of at least 50 weight % propylene units, preferably at least 70% propylene units, more preferably at least 80% propylene units, even more preferably at least 90% propylene units, even more preferably at least 95% propylene units or 100% propylene units.

As used herein, the term “heterogeneous blend” means a composition having two or more morphological phases in the same state. For example a blend of two polymers where one polymer forms discrete packets dispersed in a matrix of another polymer is said to be heterogeneous in the solid state. Also a heterogeneous blend is defined to include co-continuous blends where the blend components are separately visible, but it is unclear which is the continuous phase and which is the discontinuous phase. Such morphology is determined using scanning electron microscopy (SEM) or atomic force microscopy (AFM). In the event the SEM and AFM provide different data, then the AFM data are used. By continuous phase is meant the matrix phase in a heterogeneous blend. By discontinuous phase is meant the dispersed phase in a heterogeneous blend.

In contrast, a “homogeneous blend” is a composition having substantially one morphological phase in the same state. For example a blend of two polymers where one polymer is miscible with another polymer is said to be homogeneous in the solid state. Such morphology is determined using scanning electron microscopy. By miscible is meant that that the blend of two or more polymers exhibits single-phase behavior for the glass transition temperature, e.g. the Tg would exist as a single, sharp transition temperature on a dynamic mechanical thermal analyzer (DMTA) trace of tan δ (i.e., the ratio of the loss modulus to the storage modulus) versus temperature. By contrast, two separate transition temperatures would be observed for an immiscible blend, typically corresponding to the temperatures for each of the individual components of the blend. Thus a polymer blend is miscible when there is one Tg indicated on the DMTA trace. A miscible blend is homogeneous, while an immiscible blend is heterogeneous. The blend produced herein is generally a heterogeneous blend.

As used herein the term “slurry polymerization process” means a polymerization process where a supported catalyst is employed and monomers are polymerized on the supported catalyst particles. At least 95 wt % of polymer products derived from the supported catalyst is in granular form as solid particles (not dissolved in the diluent). A slurry process is preferred for polymers with high crystallinity. A “solution polymerization process” means a polymerization process where a homogeneous catalyst (unsupported) is used, and at least 95 wt. % of the product derived from the homogeneous catalyst is dissolved in the solvent or reaction medium. The first thermoplastic polymer may be present in the second polymerization zone in the solution process in the form of granules, as a swelled suspension or be dissolved in the reaction medium. The physical state of the first polymer in the second reaction zone depends on the reaction environment such solvent, temperature and pressure. Preferably, the polymerization condition in the second polymerization zone is chosen to allow the first polymer to be dissolved into the reaction medium.

The present invention provides a process for producing a polymer blend, particularly a heterogeneous polymer blend comprising a first phase comprising a thermoplastic first polymer, such as isotactic polypropylene, and a second elastomeric phase comprising an at least partially cross-linked second polymer, such as a blend of ethylene propylene diene rubber, dispersed within the continuous phase. In the process at least one first monomer, typically propylene, is polymerized in a first slurry phase reaction zone in the presence of a supported Ziegler Natta catalyst under conditions to produce a thermoplastic first polymer having a crystallinity of at least 30%. At least part of the first polymer is then contacted with at least one second monomer, typically ethylene, and a diene in a second solution phase reaction zone in the presence of a second catalyst, which can be a metallocene catalyst, to produce a second elastomeric polymer having a crystallinity of less than 20%.

The second elastomeric polymer, and normally the dispersed phase, of the resultant polymer blend of the invention is “at least partially cross-linked”. The presence and amount of such partially cross-linked polymer in the blend can be determined by a multi-step solvent extraction process. In this process the direct product of the polymerization process, without undergoing any additional curing steps, is first contacted with cyclohexane at 25° C. for 48 hours to dissolve the uncured and lightly branched elastomeric components of the blend and then the remaining solids are refluxed at the boiling temperature of xylene for 24 hours with xylene to isolate the “at least partially cross-linked polymer”. The “at least partially cross-linked polymer” is also referred to herein as “xylene insolubles”. Details of the solvent extraction procedure are given in the Examples.

Thus the present process allows the optimal polymerization medium for producing polypropylene, namely a slurry polymerization medium, to be combined with the optimal polymerization medium for producing an ethylene propylene diene rubber, namely a solution polymerization medium. Moreover, the slurry polymerization step employs a Ziegler-Natta catalyst to produce the polypropylene, thereby maximizing the melting temperature and molecular weight distribution of the polypropylene. In addition, a metallocene catalyst can be employed to produce the ethylene propylene diene rubber, thereby improving product physical properties due to better homogeneity and random comonomer incorporation. The metallocene catalyst can also incorporate comonomer readily without significant loss of catalyst activity or molecular weight. A conventional Ziegler-Natta or vanadium based catalyst compositions can also be used in the solution polymerization step but tends to lead to product that is less homogeneous and random as to comonomer incorporation.

The resultant product is generally a heterogeneous polymer blend, in which the thermoplastic first polymer normally constitutes the continuous phase and the second polymer is in the form of fine particles dispersed in the continuous phase. Alternatively, the second polymer is in a continuous phase while the thermoplastic first polymer appears in the dispersed phase in AFM images.

By virtue of the fact that the second polymer of the polymer blend produced by the present process is formed as at least partially cross-linked particles dispersed in the first polymer phase in the polymerization reactor, the need for a subsequent dynamic vulcanization step is avoided. It is, however, to be appreciated that in some cases the polymer blend may be subjected to post-polymerization curing and/or vulcanization to produce additional cross-linking of the second polymer.

Following the two polymerization steps, the product composition, direct from the polymerization reactor, can undergo a typical polymer finishing operation, where suitable additives are incorporated and the polymer is melt homogenized. The finished product displays easy processability, high elastic recovery, high tensile strength and elongation. Heretofore, such properties were only possible via dynamic vulcanization.

The First Polymer

The first polymer of the present polymer blend may be any crystalline or semi-crystalline thermoplastic polymer or a mixture thereof. Useful thermoplastic polymers have a crystallinity of at least 30%, more preferably at least 40% as determined by differential scanning calorimetry (DSC). The first polymer provides the composition with required tensile strength and temperature resistance. Accordingly, semi-crystalline polymers with a melting temperature, as measured by DSC, above 100° C., such as above 120° C., for example above 140° C., typically above 150° C., even above 160° C. are desired. Typically, the first polymer has a crystallization temperature (Tc) between about 20 and about 120° C., such as between about 70 and about 110° C. Polymers with a high glass transition temperature to provide the elevated temperature resistance are also acceptable as the thermoplastic matrix.

Exemplary thermoplastic polymers are crystalline polyolefins that are formed by polymerizing C₂ to C₂₀ olefins such as, but not limited to, ethylene, propylene and C₄ to C₁₂ α-olefins, and mixtures thereof. Copolymers of ethylene and propylene or ethylene or propylene with another α-olefin, may also be used.

In one embodiment, the thermoplastic polymer comprises a propylene homopolymer, a copolymer of propylene, or a mixture of propylene homopolymers and copolymers. Typically, the propylene polymer is predominately crystalline, i.e., it has a melting point generally greater than 110° C., alternatively greater than 115° C., and preferably greater than 130° C., more preferably greater than 150° C., even more preferably greater than 160° C. The term “crystalline,” as used herein, characterizes those polymers that possess high degrees of inter- and intra-molecular order in the solid state. Heat of fusion, a measure of crystallinity, greater than 60 J/g, alternatively at least 70 J/g, alternatively at least 80 J/g, as determined by DSC analysis, is preferred. The heat of fusion is dependent on the composition of the polypropylene. A propylene homopolymer will have a higher heat of fusion than a copolymer or blend of a homopolymer and copolymer.

Where the thermoplastic first polymer is polypropylene, the polymer can vary widely in composition. For example, substantially isotactic polypropylene homopolymer or propylene copolymer containing 10 weight percent or less of a comonomer can be used (i.e., at least 90% by weight propylene). Further, polypropylene segments may be part of graft or block copolymers having a sharp melting point above 110° C. and alternatively above 115° C. and alternatively above 130° C., characteristic of the stereoregular propylene sequences. When the first polymer is a propylene copolymer, the percentage of the copolymerized alpha-olefin in the copolymer is, in general, up to 9% by weight, alternatively 0.5% to 8% by weight, alternatively 2% to 6% by weight. The preferred alpha-olefins contain 2 or from 4 to 12 carbon atoms. One, two or more alpha-olefins can be copolymerized with the propylene.

The Second Polymer

The second polymer of the polymer blend is generally an elastomeric copolymer and is polymerized and also cross-linked in the presence of the first polymer. The second polymer is generally an amorphous or low crystallinity (having a crystallinity of less than 20%) polymer and in particular may include any elastomer or mixture thereof that is capable of forming a cross-linked system during the polymerization. Some non-limiting examples of suitable elastomers include olefin copolymers, butyl rubber, styrene-butadiene copolymer rubber, butadiene rubber, halogenated rubber such as brominated and chlorinated isobutylene-isoprene copolymer rubber, butadiene-styrene-vinyl pyridine rubber, urethane rubber, polyisoprene rubber, epichlolorohydrin terpolymer rubber, and polychloroprene. The second polymer can also comprise atactic polymers, such as atactic polypropylene. The preferred second polymers are elastomeric olefin copolymers.

Suitable elastomeric copolymers for use in the present blend are rubbery copolymers produced by copolymerizing two or more alpha olefins with at least one polyene, normally a diene. More typically, the elastomeric component is a copolymer of ethylene with at least one alpha-olefin monomer, and at least one diene monomer. The alpha-olefins may include, but are not limited to, C₃ to C₂₀ alpha-olefins, such as propylene, butene-1, hexene-1, 4-methyl-1 pentene, octene-1, decene-1, or combinations thereof. The preferred alpha-olefins are propylene, hexene-1, octene-1 or combinations thereof. Thus, for example, the second polymer can be an ethylene-propylene-diene (commonly called “EPDM”) rubber comprising from about 8 wt % to about 70 wt % of ethylene and at least 0.0001 wt % of the diene.

In one embodiment, the polyene has at least two unsaturated bonds that can readily be incorporated into polymers to form cross-linked polymers. Examples of such polyenes include α,ω-dienes (such as butadiene, 1,4-pentadiene, 1,5-hexadiene, 1,6-heptadiene, 1,7-octadiene, 1,8-nonadiene, 1,9-decadiene, 1,10-undecadiene, 1,11-dodecadiene, 1,12-tridecadiene, and 1,13-tetradecadiene) and certain multi-ring alicyclic fused and bridged ring dienes (such as tetrahydroindene; norbomdiene; methyl-tetrahydroindene; dicyclopentadiene; bicyclo-(2.2.1)-hepta-2,5-diene; and alkenyl-, alkylidene-, cycloalkenyl-, and cylcoalkyliene norbornenes [including, e.g., 5-methylene-2-norbornene, 5-ethylidene-2-norbornene, 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, and 5-vinyl-2-norbornene]).

In further embodiment, the polyene has at least two unsaturated bonds wherein one of the unsaturated bonds is readily incorporated into a polymer. The second bond may partially take part in polymerization to form cross-linked polymers but normally provides at least some unsaturated bonds in the polymer product suitable for subsequent functionalization (such as with maleic acid or maleic anhydride), curing or vulcanization in post polymerization processes. Examples of polyenes according to said further embodiment include, but are not limited to butadiene, pentadiene, hexadiene, heptadiene, octadiene, nonadiene, decadiene, undecadiene, dodecadiene, tridecadiene, tetradecadiene, pentadecadiene, hexadecadiene, heptadecadiene, octadecadiene, nonadecadiene, icosadiene, heneicosadiene, docosadiene, tricosadiene, tetracosadiene, pentacosadiene, hexacosadiene, heptacosadiene, octacosadiene, nonacosadiene, triacontadiene, and polybutadienes having a molecular weight (M_(w)) of less than 1000 g/mol. Examples of straight chain acyclic dienes include, but are not limited to 1,4-hexadiene and 1,6-octadiene. Examples of branched chain acyclic dienes include, but are not limited to 5-methyl-1,4-hexadiene, 3,7-dimethyl-1,6-octadiene, and 3,7-dimethyl-1,7-octadiene. Examples of single ring alicyclic dienes include, but are not limited to 1,4-cyclohexadiene, 1,5-cyclooctadiene, and 1,7-cyclododecadiene. Examples of multi-ring alicyclic fused and bridged ring dienes include, but are not limited to tetrahydroindene; norbomadiene; methyl-tetrahydroindene; dicyclopentadiene; bicyclo-(2.2.1)-hepta-2,5-diene; and alkenyl-, alkylidene-, cycloalkenyl-, and cylcoalkyliene norbornenes [including, e.g., 5-methylene-2-norbornene, 5-ethylidene-2-norbornene, 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, and 5-vinyl-2-norbornene]. Examples of cycloalkenyl-substituted alkenes include, but are not limited to vinyl cyclohexene, allyl cyclohexene, vinyl cyclooctene, 4-vinyl cyclohexene, allyl cyclodecene, vinyl cyclododecene, and tetracyclo (A-11,12)-5,8-dodecene.

In one embodiment, the catalyst employed in the first polymerization stage for production of the crystalline polymer is also capable of producing the second elastomeric copolymer in the second reaction zone. The elastomeric copolymer derived from the first supported catalyst in the second reaction zone could have different molecular weight and chemical composition from the product derived from the second catalyst. An elastomeric copolymer with bimodal distributions in molecular weight and composition could then be formed. The nature of bimodal distribution would depend on the catalyst and reaction environment in the second solution zone. The utilization of a conventional Ziegler-Natta or vanadium based catalyst composition in such polymerizations also leads to product that is a blocky (lacking in a desired level of homogeneity and randomness) as to comonomer incorporation, whereas a more homogenous or more random comonomer incorporation is generally produced when a metallocene catalyst is used.

The amount of second polymer relative to the first polymer may vary widely depending on the nature of the polymers and the intended use of the final polymer blend. In particular, however, one advantage of the process of the invention is the ability to be able to produce a heterogeneous polymer blend in which the second polymer comprises more than 50 wt %, such as more than 60 wt %, for example more than 70 wt % of the total heterogeneous polymer blend. For TPV applications, the weight ratio of the second polymer to the first polymer is generally from about 90:10 to about 50:50, more preferably from about 80:20 to about 60:40, and most preferably from about 75:25 to about 65:35. For TPO or impact copolymer applications, the weight ratio of the second polymer to the first polymer is generally from about 49:51 to about 10:90, more preferably from 35:65 to about 15:85.

In one preferred embodiment, the thermoplastic first polymer normally constitutes the continuous phase of the heterogeneous polymer blend and the second polymer is in the form of fine particles dispersed in the continuous phase. Typically, the particles of the second polymer have an average size of less than 20 micron, normally less than 10 micron, preferably less than 5 microns, more preferably less than 3 microns, for example from 50 nanometers and about 3 microns.

Production of the Polymer Blend

The present polymer blend is produced by a novel two-step process. In the first step, a crystalline thermoplastic polymer, typically containing propylene derived units, is produced by polymerizing at least one first monomer in one or more polymerization zones in the presence of a supported first catalyst in a slurry process, wherein the first catalyst comprises a Ziegler Natta catalyst component. The effluent from the first step is then fed to a second polymerization step where at least one second monomer different from the first monomer, and typically ethylene, and at least one polyene is polymerized in a solution process in the presence of the polymer produced in the first step to produce a cross-linked elastomeric component typically in the form of finely dispersed particles embedded within the crystalline thermoplastic matrix. The second polymerization step can be effected in the presence of a metallocene or a Ziegler Natta catalyst, but preferably employs a metallocene catalyst.

Conveniently, the first slurry polymerization step is conducted in a continuous, stirred tank or a loop reactor. Tubular reactors equipped with the hardware to introduce feeds, catalysts and cross-linking agents in staged manner can also be used. Generally, polymerization reactors are agitated (stirred) to reduce or avoid concentration gradients. Reaction environments include the case where the monomer(s) acts as a diluent as well as the case where a liquid hydrocarbon is used as a diluent. Preferred hydrocarbon liquids include both aliphatic and aromatic fluids such as desulphurized light virgin naphtha and alkanes, such as propane, isobutane, mixed butanes, hexane, pentane, isopentane, cyclohexane, isooctane, and octane. In an alternate embodiment a perfluorocarbon or hydrofluorocarbon is used as the diluent.

Suitable conditions for the first polymerization step include a temperature from about 50 to about 250° C., preferably from about 50 to about 150° C., more preferably from about 70 to about 150° C. and a pressure of 0.1 MPa or more, preferably 2 MPa or more. The upper pressure limit is not critically constrained but is typically 200 MPa or less, preferably, 120 MPa or less, except when operating in supercritical phase then the pressure and temperature are above the critical point of the reaction media in question ( typically over 95 ° C. and 4.6 MPa for propylene polymerizations). For more information on running supercritical polymerizations, see International Patent Publication No. WO 2004/026921. Temperature control in the reactor is generally obtained by balancing the heat of polymerization with reactor cooling via reactor jackets or cooling coils, auto refrigeration, pre-chilled feeds, vaporization of liquid medium (diluent, monomers or solvent) or combinations of all three. Adiabatic reactors with pre-chilled feeds may also be used.

In the second polymerization step, some or all of the first polymer formed in the first polymerization step, at least one second monomer, typically ethylene, and at least one cross-linking agent, typically a diene, are dissolved in a solvent and are contacted in solution with a suitable catalyst under conditions sufficient to polymerize the second monomer(s) to produce and also cross-link said second polymer. As a result of the cross-linking that occurs with the second polymerization step, the product of the second polymerization step contains at least a fraction which is insoluble in xylene. Preferably, the amount of said xylene insoluble fraction by weight of the second polymer, also referred to herein as the degree of cross-link of the second polymer, is at least 4%, such as at least 10%, such as at least 20%, such as at least 40%, such as at least 50%.

Suitable solvents for use in the second polymerization step include both aliphatic and aromatic hydrocarbon fluids. Examples of suitable, preferably inert, hydrocarbon fluids are readily volatile liquid hydrocarbons, which include, for example, saturated hydrocarbons containing from 1 to 50, preferably 3 to 20, carbon atoms. Preferred examples include propane, n-butane, isobutane, n-pentane, isopentane, neopentane, n-hexane, cyclohexane, isohexane, octane, and other saturated C₆ to C₈ hydrocarbons. Preferred hydrocarbon fluids also include alkanes (preferably C₁ to C₈ alkanes), such as propane, isobutane, mixed butanes, hexane, pentane, isopentane, desulphurized light virgin naphtha, cyclohexane and octane, are preferred. In one embodiment, the diluent further comprises at least one C₁ to C₄₀ alkane, alternatively C₂ to C₈ alkane. Typical conditions in the second polymerization zone include a temperature of about 10° C. to about 250° C. and a pressure of about 0.1 MPa to about 200 MPa.

The current process can be also carried out in a multiple-zone reactor, or separate, series-connected reactors, with the entire effluent from the first polymerization zone, including any active catalyst, being transferred to the second polymerization zone. Additional catalyst can then be added, as necessary to the second polymerization zone. Typically, the process is conducted in two or more series-connected, continuous flow, stirred tank reactors using a supported Ziegler-Natta catalyst in the first polymerization zone and a homogeneous metallocene catalyst in the second polymerization zone.

In one embodiment, catalyst quenching is applied between the two polymerization zones and a separate catalyst is introduced in the second reaction zone to produce the elastomer component. Catalyst quenching agents (such as air or an alcohol) may be introduced into the effluent from the first polymerization zone right after the reactor exit to deactivate the catalyst used for the first polymerization. Scavengers may be useful and can be fed into the effluent downstream of the catalyst quenching agent injection point or the second polymerization zone.

A polymer can be recovered from the effluent of either the first polymerization step or the second polymerization step by separating the polymer from other constituents of the effluent using conventional separation means. For example, polymer can be recovered from either effluent by coagulation with a non-solvent such as isopropyl alcohol, acetone, or n-butyl alcohol, or the polymer can be recovered by stripping the solvent or other media with heat or steam. One or more conventional additives such as antioxidants can be incorporated in the polymer during the recovery procedure. Possible antioxidants include phenyl-beta-naphthylamine; di-tert-butylhydroquinone, triphenyl phosphate, heptylated diphenylamine, 2,2′-methylene-bis (4-methyl-6-tert-butyl)phenol, and 2,2,4-trimethyl-6-phenyl-1,2-dihydroquinoline. Other methods of recovery such as by the use of lower critical solution temperature (LCST) followed by devolatilization are also envisioned. The catalyst may be deactivated as part of the separation procedure to reduce or eliminate further uncontrolled polymerization downstream the polymer recovery processes. Deactivation may be effected by the mixing with suitable polar substances such as water, whose residual effect following recycle can be counteracted by suitable sieves or scavenging systems.

The catalyst employed in the first slurry polymerization step is a Ziegler-Natta catalyst and the catalyst employed in the second solution polymerization step is preferably a single-site, metallocene catalyst. Preferred Ziegler-Natta catalysts are those capable of polymerizing a C₂ to C₂₀ olefin to produce a first polymer having at least 30% crystallinity and a peak melting temperature of 160° C. or higher.

Ziegler-Natta Catalysts

Ziegler-Natta type catalysts are catalyst compositions that incorporate Ziegler-Natta transition metal components. Typically, the transition metal component is a compound of a Group 4, 5, or 6 metal. The transition metal component is generally represented by any one of the formulas: TrX_(4-q)(OR¹)_(q), TrX_(4-q)R_(q) ² , VOX₃, and VO(OR¹)₃, wherein Tr is a Group 4, 5, or 6 metal, preferably a Group 4 or 5 metal, and more preferably titanium, vanadium or zirconium, q is 0 or a number equal to or less than 4, X is a halogen and R¹ is an alkyl group, aryl group or cycloalkyl group having from 1 to 20 carbon atoms, and R² is an alkyl group, aryl group, aralkyl group, substituted aralkyl group, and the like. The aryl, aralkyls, and substituted aralkyls contain from 1 to 20 carbon atoms, preferably 1 to 10 carbon atoms. In a preferred embodiment of the formula TrX_(4-q)R_(q) ², the hydrocarbyl group, R², does not contain an H atom in the beta position. Illustrative, but non-limiting examples of alkyl groups are methyl, neo-pentyl, 2,2-dimethylbutyl, 2,2-dimethylhexyl; aryl groups such as phenyl, naphthyl; aralkyl groups such as benzyl; cycloalkyl groups such as 1-norbornyl. Mixtures of these transition metal compounds can be employed if desired.

Illustrative examples of titanium compounds include: TiCl₄, TiBr₄, Ti(OC₂H₅)₃Cl, Ti(OC₂H₅)Cl₃, Ti(OC₄H₉)₃Cl, Ti(OC₃H₇)₂Cl₂, Ti(OC₆H₁₃)₂Cl₂, Ti(OC₁₂H₂₅)Cl₃, Ti(OC₂H₅)₂Br₂, Ti(OC₈H₁₇)₂Br₂ and TiCl₃.⅓AlCl₃. Illustrative examples of vanadium compounds include: VCl₄, VOCl₃, VO(OC₂H₅)₃, and VO(OC₄H₉)₃. Illustrative examples of zirconium compounds include: ZrCl₄, ZrCl₃(OC₂H₅), ZrCl₂(OC₂H₅)₂, ZrCl(OC₂H₅)₃, Zr(OC₂H₅)₄, ZrCl(OC₄H₉), ZrCl₂(OC₄H₉)₂, and ZrCl(OC₄H₉)₃.

Mixtures of the transition metal compounds may be usefully employed, no restriction being imposed on the number of transition metal compounds that may be incorporated. Any halogenide and alkoxide transition metal compound or mixtures thereof can be usefully employed.

Typically the Ziegler-Natta catalyst system includes a cocatalyst composition, generally comprising an organic compound of a metal of Group 1, 2, 12, or 13 of the Periodic Table. Examples of organic metal compounds employed as cocatalysts include organic compounds of lithium, magnesium, calcium, zinc, and aluminum. Organic aluminum compounds are preferred. Particularly preferred organic aluminum compounds are those represented by the general formula R_(n)AlX_(3-n) (wherein R denotes an alkyl group or an aryl group having from 1-18 carbon atoms, X denotes a halogen atom, an alkoxy group or a hydrogen atom, and n denotes a desired number in the range of 1 to 3). Examples of organic aluminum compounds include alkyl aluminum compounds such as trialkyl aluminum, dialkyl aluminum monohalide, monoalkyl aluminum dihalide, alkyl aluminum sesquihalide, dialkyl aluminum monoalkoxide, and dialkyl aluminum monohydride, respectively having 1 to 18 carbon atoms, preferably 2 to 6 carbon atoms, and mixtures and complex compounds thereof.

In one embodiment, trialkyl aluminum compounds, specifically trimethyl aluminum, triethyl aluminum, and triisobutyl aluminum, are preferred. In another embodiment, trialkyl aluminum compounds are used in combination with other organic aluminum compounds such as diethyl aluminum chloride, ethyl aluminum dichloride, ethyl aluminum sesquichloride, diethyl aluminum ethoxide, or diethyl aluminum hydride. The organic aluminum compounds may be used in the form of a mixture or complex compound.

In another embodiment, the cocatalyst is an organic aluminum compound having two or more aluminum atoms linked through an oxygen atom or nitrogen atom. Examples of such organic aluminum compounds include

Examples of organic compounds of metals other than aluminum are diethyl magnesium, ethyl magnesium chloride, diethyl zinc, and such compounds as LiAl(C₂H₅)₄ and LiAl(C₇H₁₅)₄. The ratio of organometallic compound to transition metal component will generally be in the range of from about 1 to about 100 moles of aluminum per mole of transition metal component metal on the support.

In another embodiment, the catalyst composition includes one or more alkali earth or alkali metal halide compounds. Preferably, the catalyst composition includes a titanium transition metal and one or more alkali earth or alkali metal halide compounds. Such catalyst compositions include at least one alkali earth or alkali metal halide compound in an amount to dilute titanium centers (and hence increase the active centers), stabilize active titanium centers from the deactivation process, and/or enhance the chain transfer process during polymerization. Magnesium halide is a preferred alkali earth halide. Examples of magnesium halide compounds include MgCl₂ and MgBr₂. MgCl₂, particularly anhydrous MgCl₂ is preferred. In one embodiment, from about 1 to 10 moles of magnesium chloride per mole of the titanium compound are used. Other suitable alkali earth compounds include those represented by the formula Mg(OR)₂, wherein R is an alkyl group, preferably a C₁-C₈ alkyl group, as well as the compound Mg(OH)Cl.

The Ziegler-Natta catalyst system may also contain at least one non-transition metal electron donor. Illustrative but non-limiting examples of electron donor compounds, known as “Lewis Bases,” include aliphatic and aromatic esters, aliphatic ethers, cyclic ethers, and aliphatic ketones. Examples of preferred compounds include tetrahydrofuran, dioxane, acetone, methyl formate and diethyl ether. A particularly preferred electron donor compound is tetrahydrofuran. The molar ratio of the electron donor compound to transition metal compound, particularly titanium containing compound, ranges from about 2 to 30 moles, and more preferably from about 5 to 15 moles of electron donor compound per mole of the transition metal compound.

Metallocene Catalysts

Where a metallocene catalyst system is employed in the first slurry polymerization step, the metallocene component of the system is conveniently a bridged, substituted bis(cyclopentadienyl)metallocene, specifically a bridged, substituted bis(indenyl)metallocene known to produce high molecular weight, high melting, highly isotactic propylene polymers. Particularly suitable catalysts are bridged bis-indenyl metallocene catalysts having a substituent on one or both of the 2- and 4-positions on each indenyl ring or those having a substituent on the 2-, 4-, and 7-positions on each indenyl ring. Generally speaking, those of the generic class disclosed in U.S. Pat. No. 5,770,753 (fully incorporated herein by reference) should be suitable, however, it has been found that the exact polymer obtained is dependent on the metallocene's specific substitution pattern, among other things. A specific list of useful catalyst compounds is found in International Patent Publication No. WO 2004/026921 at page 29 paragraph [00100] to page 66, line 4. In another embodiment, the catalyst compounds described in International Patent Publication No. WO 2004/026921 at page 66, paragraph [00103] to page 70, line 3 may also be used in the practice of this invention.

Particularly preferred are racemic metallocenes, such as rac-dimethylsiladiyl(2-isopropyl,4-phenylindenyl)₂ zirconium dichloride; rac-dimethylsiladiyl(2-isopropyl,4-[1-naphthyl]indenyl)₂ zirconium dichloride; rac-dimethylsiladiyl(2-isopropyl,4-[3,5-dimethylphenyl]indenyl)₂ zirconium dichloride; rac-dimethylsiladiyl(2-isopropyl,4-[ortho-methyl-phenyl]indenyl)₂ zirconium dichloride; rac-dimethylsilyl bis-(2-methyl, 4-phenylindenyl)zirconium dichoride, rac dimethylsiladlyl bis-(2-methyl, 4-napthylindenyl)zirconium dichloride, rac-dimethyl siladiyl(2-isopropyl, 4-[3,5 di-t-butyl-phenyl]indenyl)₂ zirconium dichloride; rac-dimethyl siladiyl(2-isopropyl, 4-[orthophenyl-phenyl]indenyl)₂ zirconium dichloride, rac-diphenylsiladiyl(2-methyl-4-[1-naphthyl]indenyl)₂ zirconium dichloride and rac-biphenyl siladiyl(2-isopropyl, 4-[3,5 di-t-butyl-phenyl]indenyl)₂ zirconium dichloride. Alkylated variants of these metallocenes (e.g. di-methyl instead of dichloride) are also useful, particularly when combined with a non-coordinating anion type activator. These and other metallocene compositions are described in detail in U.S. Pat. Nos. 6,376,407, 6,376,408, 6,376,409, 6,376,410, 6,376,411, 6,376,412, 6,376,413, 6,376,627, 6,380,120, 6,380,121, 6,380,122, 6,380,123, 6,380,124, 6,380,330, 6,380,331, 6,380,334, 6,399,723 and 6,825,372.

Where metallocene catalyst system is used to produce the elastomeric second polymer, this is conveniently one of, or a mixture of, metallocene compounds of either or both of the following types:

-   -   1) Cyclopentadienyl (Cp) complexes which have two Cp ring         systems for ligands. The Cp ligands form a sandwich complex with         the metal and can be free to rotate (unbridged) or locked into a         rigid configuration through a bridging group. The Cp ring         ligands can be like or unlike, unsubstituted, substituted, or a         derivative thereof such as a heterocyclic ring system which may         be substituted, and the substitutions can be fused to form other         saturated or unsaturated rings systems such as         tetrahydroindenyl, indenyl, or fluorenyl ring systems. These         cyclopentadienyl complexes are represented by the formula         (Cp¹ R¹ _(m))R³ _(n)(Cp² R² _(p))MX_(q)         wherein Cp¹ of ligand (Cp¹ R¹ _(m))and Cp² of ligand (Cp² R²         _(p)) are the same or different cyclopentadienyl rings, R¹ and         R² each is, independently, a halogen or a hydrocarbyl,         halocarbyl, hydrocarbyl-substituted organometalloid or         halocarbyl-substituted organometalloid group containing up to         about 20 carbon atoms, m is 0, 1, 2, 3, 4, or 5, p is 0, 1, 2,         3, 4 or 5, and two R¹ and/or R² substituents on adjacent carbon         atoms of the cyclopentadienyl ring associated there with can be         joined together to form a ring containing from 4 to about 20         carbon atoms, R³ is a bridging group, n is the number of atoms         in the direct chain between the two ligands and is 0, 1, 2, 3,         4, 5, 6, 7, or 8, preferably 0, 1, 2, or 3, M is a transition         metal having a valence of 3, 4, 5 or 6, preferably from Group 4,         5, or 6 of the Periodic Table of the Elements and is preferably         in its highest oxidation state, each X is a non-cyclopentadienyl         ligand and is, independently, a halogen or a hydrocarbyl,         oxyhydrocarbyl, halocarbyl, hydrocarbyl-substituted         organometalloid, oxyhydrocarbyl-substituted organometalloid or         halocarbyl-substituted organometalloid group containing up to         about 20 carbon atoms, q is equal to the valence of M minus 2.     -   2) Monocyclopentadienyl complexes which have only one Cp ring         system as a ligand. The Cp ligand forms a half-sandwich complex         with the metal and can be free to rotate (unbridged) or locked         into a rigid configuration through a bridging group to a         heteroatom-containing ligand. The Cp ring ligand can be         unsubstituted, substituted, or a derivative thereof such as a         heterocyclic ring system which may be substituted, and the         substitutions can be fused to form other saturated or         unsaturated rings systems such as tetrahydroindenyl, indenyl, or         fluorenyl ring systems. The heteroatom containing ligand is         bound to both the metal and optionally to the Cp ligand through         the bridging group. The heteroatom itself is an atom with a         coordination number of three from Group 15 or 16 of the periodic         table of the elements. These mono-cyclopentadienyl complexes are         represented by the formula         (Cp¹ R¹ _(m))R³ _(n)(Y R²)MX_(s)         wherein R¹ is, each independently, a halogen or a hydrocarbyl,         halocarbyl, hydrocarbyl-substituted organometalloid or         halocarbyl-substituted organometalloid group containing up to         about 20 carbon atoms, m is 0, 1, 2, 3, 4 or 5, and two R¹         substituents on adjacent carbon atoms of the cyclopentadienyl         ring associated therewith can be joined together to form a ring         containing from 4 to about 20 carbon atoms, R³ is a bridging         group, n is 0, or 1, M is a transition metal having a valence of         from 3, 4, 5, or 6, preferably from Group 4, 5 or 6 of the         Periodic Table of the Elements and is preferably in its highest         oxidation state, Y is a heteroatom containing group in which the         heteroatom is an element with a coordination number of three         from Group 15 or a coordination number of two from Group 16         preferably nitrogen, phosphorous, oxygen, or sulfur, R² is a         radical independently selected from a group consisting of C₁ to         C₂₀ hydrocarbon radicals, substituted C₁ to C₂₀ hydrocarbon         radicals, wherein one or more hydrogen atoms is replaced with a         halogen atom, and when Y is three coordinate and unbridged there         may be two R₂ groups on Y each independently a radical selected         from a group consisting of C₁ to C₂₀ hydrocarbon radicals,         substituted C₁ to C₂₀ hydrocarbon radicals, wherein one or more         hydrogen atoms is replaced with a halogen atom, and each X is a         non-cyclopentadienyl ligand and is, independently, a halogen or         a hydrocarbyl, oxyhydrocarbyl, halocarbyl,         hydrocarbyl-substituted organometalloid,         oxyhydrocarbyl-substituted organometalloid or         halocarbyl-substituted organometalloid group containing up to         about 20 carbon atoms, s is equal to the valence of M minus 2;         Cp¹ is a Cp ring.

Examples of suitable biscyclopentadienyl metallocenes of the type described in Group 1 above for the invention are disclosed in U.S. Pat. Nos. 5,324,800; 5,198,401; 5,278,119; 5,387,568; 5,120,867; 5,017,714; 4,871,705; 4,542,199; 4,752,597; 5,132,262; 5,391,629; 5,243,001; 5,278,264; 5,296,434; and 5,304,614, all of which are incorporated by reference herein.

Illustrative, but not limiting examples of preferred biscyclopentadienyl metallocenes of the type described in Group 1 above for the invention are the racemic isomers of: μ-(CH₃)₂ Si(indenyl)₂, M(Cl)₂μ-(CH₃)₂ Si(indenyl)₂ M(CH₃)₂, μ-(CH₃)₂ Si(tetrahydroindenyl)₂, M(Cl)₂μ-(CH₃)₂ Si(tetrahydroindenyl)₂ M(CH₃)₂, μ-(CH₃)₂ Si(indenyl)₂ M(CH₂CH₃)₂, μ-(C₆H₅)₂ C(indenyl)₂ M(CH₃)₂ wherein M is chosen from a group consisting of Zr and Hf.

Examples of suitable unsymmetrical cyclopentadienyl metallocenes of the type described in Group 1 above for the invention are disclosed in U.S. Pat. Nos. 4,892,851; 5,334,677; 5,416,228; and 5,449,651; and are described in publication J Am. Chem. Soc. 1988, 110, 6255, all of which are incorporated by reference herein.

Illustrative, but not limiting examples of preferred unsymmetrical cyclopentadienyl metallocenes of the type described in Group 1 above for the invention are:

-   μ-(C₆H₅)₂ C(cyclopentadienyl)(fluorenyl)M(R)₂ -   μ-(C₆H₅)₂ C(3-methylcyclopentadienyl)(fluorenyl)M(R)₂ -   μ-(CH₃)₂ C(cyclopentadienyl)(fluorenyl)M(R)₂ -   μ-(C₆H₅)₂ C(cyclopentadienyl)(2-methylindenyl)M(R)₂ -   μ-(C₆H₅)₂ C(3-methylcyclopentadienyl)(2-methylindenyl)M(R)₂ -   μ-(p-triethylsilylphenyl)₂C(cyclopentadienyl)(3,8-di-t-butylfluorenyl)     M(R)₂ -   μ-(C₆H₅)₂C(cyclopentadienyl)(2,7-dimethylindenyl)M(R)₂ -   μ-(CH₃)₂ C(cyclopentadienyl)(2,7-dimethylindenyl)M(R)₂.     wherein M is chosen from the group consisting of Zr and Hf and R is     chosen from the group consisting of Cl and CH₃.

Examples of suitable monocyclopentadienyl metallocenes of the type described in group 2 above for the invention are disclosed in U.S. Pat. Nos. 5,026,798; 5,057,475; 5,350,723; 5,264,405; 5,055,438 and are described in publication WO 96/002244, all of which are incorporated by reference herein.

Illustrative, but not limiting examples of preferred monocyclopentadienyl metallocenes of the type described in group 2 above for the invention are:

-   -   μ-(CH₃)₂ Si(cyclopentadienyl)(1-adamantylamido)M(R)₂     -   μ-(CH₃)₂ Si(3-tertbutylcyclopentadienyl)(1-adamantylamido)M(R)₂     -   μ-(CH₃)₂ Si(tetramethylcyclopentadienyl)(1-adamantylamido)M(R)₂     -   μ-(CH₃)₂ C(tetramethylcyclopentadienyl)(1-adamantylamido)M(R)₂     -   μ-(CH₃)₂ Si(tetramethylcyclopentadienyl)(1-tertbutylamido)M(R)₂     -   μ-(CH₃)₂ Si(fluorenyl)(1-tertbutylamido)M(R)₂     -   μ-(CH₃)₂         Si(tetramethylcyclopentadienyl)(1-cyclododecylamido)M(R)₂     -   μ-(CH₃)₂         C(tetramethylcyclopentadienyl)(1-cyclododecylamido)M(R)₂         wherein M is selected from a group consisting of Ti, Zr, and Hf         and wherein R is selected from Cl and CH₃.

The manner of activation of the metallocene catalyst used in the first or second polymerization step can vary. Alumoxane and preferably methyl alumoxane (MAO) can be used. Non-or weakly coordinating anion activators (NCA) may be obtained in any of the ways described in EP277004, EP426637. Activation generally is believed to involve abstraction of an anionic group such as the methyl group to form a metallocene cation, although according to some literature zwitterions may be produced. The NCA precursor can be an ion pair of a borate or aluminate in which the precursor cation is eliminated upon activation in some manner, e.g. trityl or ammonium derivatives of tetrakis pentafluorophenyl boron (See EP277004). The NCA precursor can be a neutral compound such as a borane, which is formed into a cation by the abstraction of and incorporation of the anionic group abstracted from the metallocene (See EP426638).

The alumoxane activator may be utilized in an amount to provide a molar aluminum to metallocene ratio of from 1:1 to 20,000:1 or more. The non-coordinating compatible anion activator may be utilized in an amount to provide a molar ratio of metallocene compound to non-coordinating anion of 10:1 to 1:1.

Particularly useful activators include dimethylaniliniumtetrakis (pentafluorophenyl) borate and dimethyl anilinium tetrakis(heptafluoro-2-naphthyl)borate. For a more detailed description of useful activators see International Patent Publication No. WO 2004/026921 at page 72, paragraph [00119] to page 81 paragraph [00151]. A list of particularly useful activators that can be used in the practice of this invention may be found at page 72, paragraph [00177] to page 74, paragraph [00178] of International Patent Publication No. WO 2004/046214.

Catalyst Supports

The Ziegler-Natta catalyst system used to produce the first thermoplastic polymer comprises a support material. The support material can be any solid, particularly porous support material such as talc or inorganic oxides, or resinous support materials such as a polyolefin. Preferably, the support material is an inorganic oxide.

Examples of suitable inorganic oxide materials include Group 2, 4, 13, 14 metal oxides such as silica, alumina, silica-alumina and mixtures thereof. Other inorganic oxides that may be employed either alone or in combination with the silica, alumina or silica-alumina are magnesia, titania, zirconia, and the like. Other suitable support materials, however, can be employed, for example, polyolefins such as polyethylene.

Preferably the support material is porous silica which has a surface area in the range of from 10 to 700 m²/g, a total pore volume in the range of from 0.1 to 4.0 cc/g and an average particle size in the range of from 10 to 500 μm. More preferably, the surface area is in the range of from 50 to 500 m²/g, the pore volume is in the range of from 0.5 to 3.5 cc/g and the average particle size is in the range of from 20 to 200 μm. Most desirably the surface area is in the range of from 100 to 400 m²/g, the pore volume is in the range of from 0.8 to 3.0 cc/g and the average particle size is in the range of from 30 to 100 μm. The average pore size of typical porous support materials is in the range of from 10 to 1000 Angstrom. Preferably, a support material is used that has an average pore diameter of from 50 to 500 Angstrom, and most desirably from 75 to 350 Angstrom.

In one embodiment, the inorganic oxide support is any particulate oxide or mixed oxide that has been thermally or chemically dehydrated such that it is substantially free of moisture. Thermal treatment is preferably carried out in vacuum or while purging with a dry inert gas such as nitrogen at a temperature of about 100° C. to about 1000° C., and preferably from about 300° C. to about 800° C. Pressure considerations are not critical. The duration of the thermal treatment can be from about 1 to about 24 hours; however, shorter or longer times can be employed provided equilibrium is established with the surface hydroxyl groups.

Chemical dehydration as an alternative method of dehydration of the metal oxide support material can advantageously be employed. Chemical dehydration converts water and hydroxyl groups on the oxide surface to inert species. Useful chemical agents include, for example, SiCl₄, and chlorosilanes, such as trimethylchlorosilane, dimethyaminotrimethylsilane and the like. Chemical dehydration is accomplished by slurrying the inorganic particulate material, for example, silica in an inert low boiling hydrocarbon, such as, hexane. During the chemical dehydration reaction, the silica should be maintained in a moisture and oxygen-free atmosphere. To the silica slurry is then added a low boiling inert hydrocarbon solution of the chemical dehydrating agent, such as, dichlorodimethylsilane. Preferably, the temperature ranges during chemical dehydration reaction are from about 25° C. to about 120° C.; however, higher and lower temperatures can be employed. Preferably, the temperature will be about 50° C. to about 70° C.

The chemical dehydration procedure should be allowed to proceed until sufficient moisture is removed from the particulate support material as indicated by cessation of gas evolution. Normally, the chemical dehydration reaction will be allowed to proceed from about 30 minutes to about 16 hours, preferably 1 to 5 hours. Upon completion of the chemical dehydration, the solid particulate material is filtered under a nitrogen atmosphere and washed one or more times with a dry, oxygen-free inert hydrocarbon solvent. The wash solvents, as well as the diluents employed to form the slurry and the solution of chemical dehydrating agent, can be any suitable inert hydrocarbon. Illustrative of such hydrocarbons are heptane, hexane, toluene, isopentane and the like.

In another embodiment, the support material may be surface modified. Surface modification is preferably accomplished by treating the support material such as silica, alumina or silica-alumina with an organometallic compound having hydrolytic character. More particularly, the surface modifying agents for the support materials comprise the organometallic compounds of the metals of Group 2 and 13 of the Periodic Table. Most preferably the organometallic compounds are selected from magnesium and aluminum organometallics and especially from magnesium and aluminum alkyls or mixtures thereof represented by the formulas R¹MgR² and R¹R²AlR³ wherein each of R¹, R² and R³ are the same or different alkyl groups, aryl groups, cycloalkyl groups, aralkyl groups, alkoxide groups alkadienyl groups or alkenyl groups. The hydrocarbon groups R¹, R² and R³ preferably contain from 1 to 20 carbon atoms and more preferably from 1 to 10 carbon atoms.

Conveniently, the organometallic compound is added in a suitable solvent to a slurry of the support material. Contact of the organometallic compound in a suitable solvent and the support is preferably maintained for about 30 to 180 minutes and preferably for 60 to 90 minutes at a temperature in the range of from 20° C. to 100° C. The diluent employed in slurrying the support can be any of the solvents employed in solubilizing the organometallic compound and is preferably the same.

The amount of surface modifying agent employed in preparation of the surface modified support material can vary over a wide range. Generally the amount will be in the range of from 1×10⁻⁶ moles to about 2×10⁻³ moles of modifying agent per gram of support material. However greater or lesser amounts can be employed.

Illustrative, but non-limiting examples of magnesium compounds which may be suitably employed as surface modifying agents include dialkyl magnesiums such as diethylmagnesium, dipropylmagnesiums, di-isopropylmagnesium, di-n-butylmagnesium, di-isobutylmagnesium, diamylmagnesium, di-n-octylmagnesium, di-n-hexyhnagnesium, di-n-decylmagnesium, and di-n-dodecylmagnesium; dicycloalkylmagnesiums, such as dicyclohexylmagnesium; diarylmagnesiums such as dibenzylmagnesium, ditolylmagnesium, and dixylylmagnesium, alkylalkoxy magnesium such as ethyl magnesium ethoxide and the like.

Illustrative, but non-limiting examples of aluminum compounds which may be suitably employed surface modifying agents include trialkylaluminums such as trimethylaluminum, triethylaluminum, tripropylaluminum, triisobutylaluminum, tri-n-hexylaluminum, and tri-n-octylaluminum. Preferably, the organoaluminum compounds are trimethylaluminum, triisobutylaluminum, and triethylaluminum.

Preferably, the surface modifying agent is an organomagnesium compound of the formula R¹MgR² wherein each of R¹ and R² is a hydrocarbyl group having from one to six carbon atoms and most preferably R¹ and R² are different. Illustrative examples of preferred magnesium compounds include ethyl-n-propylmagnesium, ethyl-n-butylmagnesium, amyl-n-hexylmagnesium, n-butyl-sec-butylmagnesium, n-butyl-n-octylmagnesium and the like. Mixtures of hydrocarbylmagnesium compounds may be suitably employed such as, for example, di-n-butylmagnesium and ethyl-n-butylmagnesium.

Magnesium hydrocarbyl compounds are generally obtained from commercial sources as mixtures of the magnesium hydrocarbon compound with a minor amount of aluminum hydrocarbyl compound. A minor amount of aluminum hydrocarbyl is preferably present in order to facilitate solubilization and/or reduce the viscosity of the organomagnesium compound in hydrocarbon solvent. The hydrocarbon solvent usefully employed for the organomagnesium compound can be any of the well known hydrocarbon liquids, for example, hexane, heptane, octane, decane, dodecane, or mixtures thereof, as well as aromatic hydrocarbons such as benzene, toluene, xylene, etc.

A preferred organomagnesium complex with a minor amount of aluminum alkyl is represented by the formula (R¹Mg²)_(x)(R₃ ⁴Al)_(y) wherein R¹ and R² are defined as above, R⁴ is defined as R¹ and R² and x is greater than 0. The ratio of y to (y+x) is from 0 to less than 1, preferably from 0 to about 0.7 and most desirably from about 0 to 0.1. Illustrative examples of preferred organomagnesium-organoaluminum complexes are [(n-C₄H₉)(C₂H₅)Mg][(C₂H₅)₃Al]_(0.02), [(n-C₄H₉)₂Mg][(C₂H₅)₃Al]_(0.013), [(n-C₄H₉)₂Mg][(C₂H₅)₃Al]_(2.0) and [(n-C₆H₁₃)₂Mg][C₂H₅)Al]_(0.01).

Hydrocarbon soluble organomagnesium materials can be prepared by conventional methods. One such method involves, for example, the addition of an appropriate aluminum alkyl to a solid dialkylmagnesium in the presence of an inert hydrocarbon solvent. The organomagnesium-organoaluminum complexes are further described in the literature, for example in U.S. Pat. Nos. 3,737,393 and 4,004,071, the detailed descriptions of each being incorporated herein by reference. However, any other suitable method for preparation of organometallic compound may be employed.

The supported catalyst precursors may also pre-activated to influence the morphology, and in particular the bulk density, of polymer products produced. In one embodiment, the supported catalyst precursors are pre-activated with alumoxane and/or various bulky aluminum alkyls at an activator to transition metal, particularly titanium, molar ratio of from about 0.1 to about 15, more preferably about 0.1 to 10. Pre-activation can be achieved using a hydrocarbon slurry medium typically at temperatures from about 15° C. to 30° C. with continuous mixing followed by drying at temperatures between about 30° C. to 100° C., and preferably about 50° C. to 80° C., to obtain a free-flowing solid. Illustrative but non-limiting examples of pre-activating agents include diethyl aluminum chloride (DEAC), trihexyl aluminum (TnHAL), trioctyl aluminum (TNOA), methyl aluminoxane (MAO), and mixtures thereof.

Activation of the pre-activated catalyst precursor, prior to polymerization, can be accomplished by feeding a slurry of the pre-activated precursor into a suitable reactor under a nitrogen atmosphere, typically in an inert hydrocarbon diluent, such as hexane, heptane, isopentane, toluene, mineral oil or other hydrocarbons known to be useful in the field, followed by the addition of an alumoxane-based cocatalyst. The cocatalyst is preferably diluted with from about 2 to 40 weight percent of a hydrocarbon solvent similar to the one used to slurry the pre-activated catalyst, and is subsequently added to the reactor as a solution. Preferably, the total molar ratio of aluminum to transition metal, preferably titanium, in the system is from 5 to 300, preferably from about 100 to about 250, and more preferably from 50 to 150, depending on the specific embodiment. Illustrative but non-limiting examples of the cocatalyst systems employed in the present invention include, but are not limited to, physical mixtures of alumoxane including polymeric methyl aluminoxane (MAO), co-polymeric isobutyl methyl aluminoxane (CoMAO), and mixtures of MAO or CoMAO along with conventional trialkyl aluminum compounds, such as triethyl aluminum (TEAL), tri-isobutyl aluminum (TIBA), trimethyl aluminum (TMA), trihexyl aluminum, diethyl aluminum chloride and mixtures thereof, said physical mixtures of alumoxane and trialkyl aluminum compounds comprising 10 to 90 mole percent alumoxane, and preferably 10 to 50 mole percent alumoxane, wherein the mole percent corresponds to the molar ratios of aluminum from each compound.

In-Reactor Produced Polymer Blend

By virtue of the novel polymerization process used in its production, the polymer blend produced by the present process not only comprises particles of the second polymer dispersed within a matrix of the first thermoplastic polymer but also at least a portion the dispersed phase is cross-linked. In addition, it is found that the particles of the second polymer tend be more evenly distributed and have a broader particle size distribution, than products obtained by conventional reactive extrusion techniques.

In addition, since at least some cross-linking of the dispersed phase occurs during the second polymerization step, rather than all the cross-linking being effected in a subsequent dynamic extrusion step, the dispersed phase of the heterogeneous polymer blend of the invention comprises at least a fraction which is insoluble in xylene and which is substantially free of the curatives normally added to polymers blends to effect cross-linking during post-polymerization, dynamic extrusion. By substantially free is meant that the dispersed phase contains less than 1,000 ppm, such as less than 1000 ppm, such as less than 10 ppm, of a curative.

Polymers with bimodal distributions of molecular weight and composition can be produced by the polymerization process of the invention, by, for example, controlling the polymerization conditions in the first and the second polymerization zones and selecting the catalysts for the first and the second polymerizations, such as by using multiple catalysts in each polymerization zone.

Generally, olefins are present in the elastomeric dispersed phase of the heterogeneous polymer blend of the invention at levels from about 95 to about 99.99 wt %, whereas the diene content of the elastomeric copolymer is from about 0.01 wt % to about 5 wt %. But specific embodiments can have a variety of diene contents. Some embodiments have two or more different olefin units in the elastomeric component, with at least one monomer being selected from ethylene, propylene and C₄ to C₂₀ alpha-olefins. Typically, said at least one monomer unit comprises ethylene and a further monomer is selected from propylene and C₄ to C₁₂ alpha-olefins, especially propylene. These embodiments typically have one olefin present in amounts of from 12 to 88 wt %, for example from 30 to 70 wt %, of the copolymer whereas the other olefin is present in amounts of from 88 to 12 wt %, for example from 70 to 30 wt %, of the copolymer.

Still more desirably, the elastomeric copolymer includes: ethylene units in the range from 12 wt % to 88 wt % of the copolymer; propylene or other α-olefin(s) units in the range from 88 wt % to 12 wt %, desirably ethylene units in the range from 30 to 70 wt % and propylene or other α-olefin(s) units in the range from 70 to 30 wt %; more desirably ethylene units in the range from 40 wt % to 60 wt % and propylene or other α-olefin(s) units in the range from 60 to 40 wt % of the copolymer.

The individual components of the heterogeneous polymer blend produced by the present process can readily be separated by solvent extraction. In a suitable solvent extraction regime, the blend, without undergoing any additional processing steps, is contacted with cyclohexane at 25° C. for 48 hours to dissolve the uncured and branched elastomeric components of the blend and then the remaining solids are refluxed at the boiling temperature of xylene for 24 hours with xylene to dissolve the continuous thermoplastic phase material. The remaining xylene insolubles comprise the cross-linked second polymer.

In one embodiment, the polymer blend described herein has a tensile strength at break (as measured by ISO 37 at 23° C.) of 0.5 MPa or more, alternatively 0.75 MPa or more, alternatively 1.0 MPa or more, alternatively 1.5 MPa or more, alternatively 2.0 MPa or more, alternatively 2.5 MPa or more, alternatively 3.0 MPa or more, alternatively 3.5 MPa or more.

In another embodiment, the polymer blend described herein has a Shore hardness of 10 A to 90 D, preferably 15 A to 90 D (as measured by ISO 868).

In another embodiment, the polymer blend described herein has an ultimate elongation (as measured by ISO 37) of 20% or more, preferably 50% or more, more preferably 100% or more.

In another embodiment, the polymer blend described herein has a compression set (as measured by ISO 815A) of 90% or less, preferably 70% or less, more preferably 50% or less, more preferably 30% or less, more preferably 20% or less.

In another embodiment, the polymer blend described herein has a tension set (as measured by ISO 2285) of 100% or less, preferably 80% or less, more preferably 60% or less, more preferably 40% or less, more preferably 30% or less, more preferably 20% or less.

In another embodiment, the polymer blend described herein has an oil swell (as measured by ASTM D471) of 500% or less, preferably 250% or less, more preferably 100% or less.

Additives

The polymer blend produced by the present process may optionally be combined with one or more additives selected from reinforcing and non-reinforcing fillers, plasticizers, antioxidants, stabilizers, rubber processing oils, extender oils, lubricants, antiblocking agents, antistatic agents, waxes, foaming agents, pigments, flame retardants and other processing aids known in the rubber compounding art. Such additives may comprise up to about 70 weight percent, more preferably up to about 65 weight percent, of the total composition. Fillers and extenders which can be utilized include conventional inorganics such as calcium carbonate, clays, silica, talc, titanium dioxide, carbon black and the like. The rubber processing oils generally are paraffinic, naphthenic or aromatic oils derived from petroleum fractions. The oils are selected from those ordinarily used in conjunction with the specific rubber or rubber component present in the composition.

The additives such as fillers and oils can be introduced into the polymer blend during the polymerization in either the first polymerization zone or the second polymerization zone. The additives can be added into the effluent from the second polymerization zone and are preferably added into the polymer blend after removal of solvent or diluent through melt blending.

Additional polymers can also be added to form blends. In one or more embodiments, the additional polymers include thermoplastic resins. Exemplary thermoplastic resins include crystalline polyolefins. Also, suitable thermoplastic resins may include copolymers of polyolefins with styrene, such as a styrene-ethylene copolymer. In one or more embodiments, the thermoplastic resins are formed by polymerizing ethylene or α-olefins or mixtures thereof. Copolymers of ethylene and propylene and ethylene and propylene with another α-olefin or mixtures thereof are also contemplated. Specifically included are the homopolypropylene, impact, and random copolymers of propylene with ethylene or the higher α-olefins, described above, or with C₁₀-C₂₀ diolefins. Preferably, the homopolypropylene has a melting point of at least 130° C., for example at least 140° C. and preferably less than or equal to 170° C., a heat of fusion of at least 75 J/g, alternatively at least 80 J/g, as determined by DSC analysis, and weight average molecular weight (Mw) of at least 50,000, alternatively at least 100,000. Comonomer contents for these propylene copolymers will typically be from 1 to about 30% by weight of the polymer, for example, See U.S. Pat. Nos. 6,268,438, 6,288,171, and 6,245,856. Copolymers available under the tradename VISTAMAXX™ (ExxonMobil) are specifically included. Blends or mixtures of two or more polyolefin thermoplastics such as described herein, or with other polymeric modifiers, are also suitable in accordance with this invention. These homopolymers and copolymers may be synthesized by using an appropriate polymerization technique known in the art such as, but not limited to, the conventional Ziegler-Natta type polymerizations, and catalysis employing single-site organometallic catalysts including, but not limited to, metallocene catalysts.

In one or more embodiments, the polyene can be selected such that any pendant double bond left unreacted can undergo thermal cross-linking during the finishing operation thereby increasing the crosslink density of the rubber phase.

In one or more embodiments, during the finishing step cross-linking agents can be injected into the polymer finishing equipment to increase the cure density of the dispersed rubber phase. Exemplary curatives include phenolic resin cure systems, peroxide cure systems, and silicon-containing cure systems

In one or more embodiments, the phenolic resins include those disclosed in U.S. Pat. Nos. 2,972,600, 3,287,440, 5,952,425 and 6,437,030, and PCT/US04/30518, which are incorporated herein by reference.

Phenolic resin curatives can be referred to as resole resins, and include those resins made by the condensation of alkyl substituted phenols or unsubstituted phenols with aldehydes, such as formaldehydes, in an alkaline medium or by condensation of bi-functional phenoldialcohols. The alkyl substituents of the alkyl substituted phenols may contain 1 to about 10 carbon atoms. Dimethylolphenols or phenolic resins, substituted in para-positions with alkyl groups containing 1 to about 10 carbon atoms are preferred. In one embodiment, a blend of octyl phenol and nonylphenol-formaldehyde resins are employed. The blend may include from about 25 to about 40% by weight octyl phenol and from about 75 to about 60% by weight nonylphenol (optionally from about 30 to about 35 weight percent octyl phenol and from about 70 to about 65 weight percent nonylphenol). In one embodiment, the blend includes about 33% by weight octylphenol-formaldehyde and about 67% by weight nonylphenol formaldehyde resin, where each of the octylphenol and nonylphenol include methylol groups. This blend can be solubilized in paraffinic oil at about 30% solids.

Useful phenolic resins may be obtained under the tradenames SP-1044, SP-1045 (Schenectady International; Schenectady, N.Y.), which are referred to as alkylphenol-formaldehyde resins. SP-1045 is believed to be an octylphenol-formaldehyde resin that contains methylol groups. The SP-1044 and SP-1045 resins are believed to be essentially free of halogen substituents or residual halogen compounds. By essentially free of halogen substituents, it is meant that the synthesis of the resin provides for a non-halogenated resin that may only contain trace amounts of halogen containing compounds.

In one or more embodiments, the phenolic resin can be used in combination with the halogen source, such as stannous chloride, and a metal oxide or reducing compound such as zinc oxide.

In one or more embodiments, useful peroxide curatives include organic peroxides. Examples of organic peroxides include, but are not limited to, di-tert-butyl peroxide, dicumyl peroxide, t-butylcumyl peroxide, α,α-bis(tert-butylperoxy)diisopropyl benzene, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane (DBPH), 1,1-di(tert-butylperoxy)-3,3,5-trimethyl cyclohexane, n-butyl-4-4-bis(tert-butylperoxy)valerate, benzoyl peroxide, lauroyl peroxide, dilauroyl peroxide, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3, and mixtures thereof. Also, diaryl peroxides, ketone peroxides, peroxydicarbonates, peroxyesters, dialkyl peroxides, hydroperoxides, peroxyketals and mixtures thereof may be used. Useful peroxides and their methods of use in dynamic vulcanization of thermoplastic vulcanizates are disclosed in U.S. Pat. No. 5,656,693, which is incorporated herein by reference.

In one or more embodiments, the peroxide curatives are employed in conjunction with a coagent. Examples of coagents include triallylcyanurate, triallyl isocyanurate, triallyl phosphate, sulfur, N-phenyl bis-maleamide, zinc diacrylate, zinc dimethacrylate, divinyl benzene, 1,2 polybutadiene, trimethylol propane trimethacrylate, tetramethylene glycol diacrylate, trifunctional acrylic ester, dipentaerythritolpentacrylate, polyfunctional acrylate, retarded cyclohexane dimethanol diacrylate ester, polyfunctional methacrylates, acrylate and methacrylate metal salts, oximer for e.g., quinone dioxime. In order to maximize the efficiency of peroxide/coagent crosslinking the mixing and dynamic vulcanization are preferably carried out in a nitrogen atmosphere.

In one or more embodiments, useful silicon-containing cure systems include silicon hydride compounds having at least two SiH groups. It is believed that these compounds react with carbon-carbon double bonds of unsaturated polymers in the presence of a hydrosilation catalyst. Silicon hydride compounds that are useful in practicing the present invention include, but are not limited to, methylhydrogen polysiloxanes, methylhydrogen dimethyl-siloxane copolymers, alkyl methyl polysiloxanes, bis(dimethylsilyl)alkanes, bis(dimethylsilyl)benzene, and mixtures thereof.

Useful catalysts for hydrosilation include, but are not limited to, peroxide catalysts and catalysts including transition metals of Group VIII. These metals include, but are not limited to, palladium, rhodium, and platinum, as well as complexes of these metals. For a further discussion of the use of hydrosilation to cure thermoplastic vulcanizates, reference can be made to U.S. Pat. No. 5,936,028, which is incorporated herein by reference. In one or more embodiments, a silicon-containing curative can be employed to cure an elastomeric copolymer including units deriving from 5-vinyl-2-norbornene.

In one or more embodiments, curatives that are useful for curing the inventive polymer blend include those described in U.S. Pat. Nos. 5,013,793, 5,100,947, 5,021,500, 4,978,714, and 4,810,752, which are incorporated herein by reference.

Uses of the Polymer Blends

The polymer blends described herein may be shaped into desirable end use articles by any suitable means known in the art. They are particularly useful for making articles by blow molding, extrusion, injection molding, thermoforming, gas foaming, elasto-welding and compression molding techniques.

Thermoforming is a process of forming at least one pliable plastic sheet into a desired shape. An embodiment of a thermoforming sequence is described, however this should not be construed as limiting the thermoforming methods useful with the compositions of this invention. First, an extrudate film of the composition of this invention (and any other layers or materials) is placed on a shuttle rack to hold it during heating. The shuttle rack indexes into the oven which pre-heats the film before forming. Once the film is heated, the shuttle rack indexes back to the forming tool. The film is then vacuumed onto the forming tool to hold it in place and the forming tool is closed. The forming tool can be either “male” or “female” type tools. The tool stays closed to cool the film and the tool is then opened. The shaped laminate is then removed from the tool.

Thermoforming is accomplished by vacuum, positive air pressure, plug-assisted vacuum forming, or combinations and variations of these, once the sheet of material reaches thermoforming temperatures, typically of from 140° C. to 185° C. or higher. A pre-stretched bubble step is used, especially on large parts, to improve material distribution. In one embodiment, an articulating rack lifts the heated laminate towards a male forming tool, assisted by the application of a vacuum from orifices in the male forming tool. Once the laminate is firmly formed about the male forming tool, the thermoformed shaped laminate is then tooled, typically by blowers. Plug-assisted forming is generally used for small, deep drawn parts. Plug material, design, and timing can be critical to optimization of the process. Plugs made from insulating foam avoid premature quenching of the plastic. The plug shape is usually similar to the mold cavity, but smaller and without part detail. A round plug bottom will usually promote even material distribution and uniform side-wall thickness.

The shaped laminate is then cooled in the mold. Sufficient cooling to maintain a mold temperature of 30° C. to 65° C. is desirable. The part is below 90° C. to 100° C. before ejection in one embodiment. For the good behavior in thermoforming, the lowest melt flow rate polymers are desirable. The shaped laminate is then trimmed of excess laminate material.

Blow molding is another suitable forming means, which includes injection blow molding, multi-layer blow molding, extrusion blow molding, and stretch blow molding, and is especially suitable for substantially closed or hollow objects, such as, for example, gas tanks and other fluid containers. Blow molding is described in more detail in, for example, CONCISE ENCYCLOPEDIA OF POLYMER SCIENCE AND ENGINEERING 90-92 (Jacqueline I. Kroschwitz, ed., John Wiley & Sons 1990).

In yet another embodiment of the formation and shaping process, profile co-extrusion can be used. The profile co-extrusion process parameters are as above for the blow molding process, except the die temperatures (dual zone top and bottom) range from 150° C. to 235° C., the feed blocks are from 90° C. to 250° C., and the water cooling tank temperatures are from 10° C. to 40° C.

One embodiment of an injection molding process is described as follows. The shaped laminate is placed into the injection molding tool. The mold is closed and the substrate material is injected into the mold. The substrate material has a melt temperature between 200° C. and 300° C., such as between 215° C. and 250° C. and is injected into the mold at an injection speed of between 2 and 10 seconds. After injection, the material is packed or held at a predetermined time and pressure to make the part dimensionally and aesthetically correct. Typical time periods are from 5 to 25 seconds and pressures from 1,380 kPa to 10,400 kPa. The mold is cooled between 10° C. and 70° C. to cool the substrate. The temperature will depend on the desired gloss and appearance desired. Typical cooling time is from 10 to 30 seconds, depending on part on the thickness. Finally, the mold is opened and the shaped composite article ejected.

Likewise, molded articles may be fabricated by injecting molten polymer into a mold that shapes and solidifies the molten polymer into desirable geometry and thickness of molded articles. Sheet may be made either by extruding a substantially flat profile from a die, onto a chill roll, or alternatively by calendaring. Sheet will generally be considered to have a thickness of from 10 mils to 100 mils (254 μm to 2540 μm), although sheet may be substantially thicker. Tubing or pipe may be obtained by profile extrusion for uses in medical, potable water, land drainage applications or the like. The profile extrusion process involves the extrusion of molten polymer through a die. The extruded tubing or pipe is then solidified by chill water or cooling air into a continuous extruded articles. The tubing will generally be in the range of from 0.31 cm to 2.54 cm in outside diameter, and have a wall thickness of in the range of from 254 cm to 0.5 cm. The pipe will generally be in the range of from 2.54 cm to 254 cm in outside diameter, and have a wall thickness of in the range of from 0.5 cm to 15 cm. Sheet made from the products of an embodiment of a version of the present invention may be used to form containers. Such containers may be formed by thermoforming, solid phase pressure forming, stamping and other shaping techniques. Sheets may also be formed to cover floors or walls or other surfaces.

In an embodiment of the thermoforming process, the oven temperature is between 160° C. and 195° C., the time in the oven between 10 and 20 seconds, and the die temperature, typically a male die, between 10° C. and 71° C. The final thickness of the cooled (room temperature), shaped laminate is from 10 μm to 6000 μm in one embodiment, from 200 μm to 6000 μm in another embodiment, and from 250 μm to 3000 μm in yet another embodiment, and from 500 μm to 1550 μm in yet another embodiment, a desirable range being any combination of any upper thickness limit with any lower thickness limit.

In an embodiment of the injection molding process, wherein a substrate material is injection molded into a tool including the shaped laminate, the melt temperature of the substrate material is between 230° C. and 255° C. in one embodiment, and between 235° C. and 250° C. in another embodiment, the fill time from 2 to 10 seconds in one embodiment, from 2 to 8 seconds in another embodiment, and a tool temperature of from 25° C. to 65° C. in one embodiment, and from 27° C. and 60° C. in another embodiment. In a desirable embodiment, the substrate material is at a temperature that is hot enough to melt any tie-layer material or backing layer to achieve adhesion between the layers.

In yet another embodiment of the invention, the compositions of this invention may be secured to a substrate material using a blow molding operation. Blow molding is particularly useful in such applications as for making closed articles such as fuel tanks and other fluid containers, playground equipment, outdoor furniture and small enclosed structures. In one embodiment of this process, Compositions of this invention are extruded through a multi-layer head, followed by placement of the uncooled laminate into a parison in the mold. The mold, with either male or female patterns inside, is then closed and air is blown into the mold to form the part.

It will be understood by those skilled in the art that the steps outlined above may be varied, depending upon the desired result. For example, an extruded sheet of the compositions of this invention may be directly thermoformed or blow molded without cooling, thus skipping a cooling step. Other parameters may be varied as well in order to achieve a finished composite article having desirable features.

The thermoplastic elastomer blends described herein are useful for making a variety of articles such as weather seals, hoses, belts, gaskets, moldings, boots, elastic fibers and like articles. Foamed end-use articles are also envisioned. More specifically, the blends of the invention are particularly useful for making vehicle parts, such as but not limited to, weather seals, brake parts including, but not limited to cups, coupling disks, diaphragm cups, boots such as constant velocity joints and rack and pinion joints, tubing, sealing gaskets, parts of hydraulically or pneumatically operated apparatus, o-rings, pistons, valves, valve seats, valve guides, and other elastomeric polymer based parts or elastomeric polymers combined with other materials such as metal, plastic combination materials which will be known to those of ordinary skill in the art. Also contemplated are transmission belts including V-belts, toothed belts with truncated ribs containing fabric faced V's, ground short fiber reinforced Vs or molded gum with short fiber flocked V's. The cross section of such belts and their number of ribs may vary with the final use of the belt, the type of market and the power to transmit. They also can be flat made of textile fabric reinforcement with frictioned outside faces. Vehicles contemplated where these parts will find application include, but are not limited to passenger autos, motorcycles, trucks, boats and other vehicular conveyances.

In the Examples, molecular weights (number average molecular weight (Mn), weight average molecular weight (Mw), and z-average molecular weight (Mz)) were determined using a Waters 150 Size Exclusion Chromatograph (SEC) equipped with a differential refractive index detector (DRI), an online low angle light scattering (LALLS) detector and a viscometer (VIS). The details of these detectors as well as their calibrations have been described by, for example, T. Sun, P. Brant, R. R. Chance, and W. W. Graessley, in Macromolecules, Volume 34, Number 19, 6812-6820, (2001), incorporated herein by reference. Solvent for the SEC experiment was prepared by adding 6 grams of butylated hydroxy toluene (BHT) as an antioxidant to a 4 liter bottle of 1,2,4 trichlorobenzene (TCB) (Aldrich Reagent grade) and waiting for the BHT to solubilize. The TCB mixture was then filtered through a 0.7 micron glass pre-filter and subsequently through a 0.1 micron Teflon filter. There was an additional online 0.7 micron glass pre-filter/0.22 micron Teflon filter assembly between the high pressure pump and SEC columns. The TCB was then degassed with an online degasser (Phenomenex, Model DG-4000) before entering the SEC. Polymer solutions were prepared by placing dry polymer in a glass container, adding the desired amount of TCB, then heating the mixture at 160° C. with continuous agitation for about 2 hours. All quantities were measured gravimetrically. The TCB densities used to express the polymer concentration in mass/volume units were 1.463 g/ml at room temperature and 1.324 g/ml at 135° C. The injection concentration ranged from 1.0 to 2.0 mg/ml, with lower concentrations being used for higher molecular weight samples.

The branching index in the Examples was measured using SEC with an on-line viscometer (SEC-VIS) and is reported as g′ at each molecular weight in the SEC trace. The branching index g′ is defined as:

$g^{\prime} = \frac{\eta_{b}}{\eta_{l}}$ where η_(b) is the intrinsic viscosity of the branched polymer and η₁ is the intrinsic viscosity of a linear polymer of the same viscosity-averaged molecular weight (M_(v)) as the branched polymer all η₁=KM_(v) ^(α), K and α were measured values for linear polymers and should be obtained on the same SEC-DRI-LS-VIS instrument as the one used for branching index measurement. For polypropylene samples used in this process, K=0.0002288 and α=0.705 were used. The SEC-DRI-LS-VIS method obviates the need to correct for polydispersities, since the intrinsic viscosity and the molecular weight were measured at individual elution volumes, which arguably contain narrowly dispersed polymer. Linear polymers selected as standards for comparison should be of the same viscosity average molecular weight, monomer content and composition distribution. Linear character for polymer containing C2 to C10 monomers is confirmed by Carbon-13 NMR using the method of Randall (Rev. Macromol. Chem. Phys., C29 (2&3), p. 285-297). Linear character for C11 and above monomers is confirmed by GPC analysis using a MALLS detector. For example, for a copolymer of propylene, the NMR should not indicate branching greater than that of the co-monomer (i.e. if the comonomer is butene, branches of greater than two carbons should not be present). For a homopolymer of propylene, the GPC should not show branches of more than one carbon atom. When a linear standard is desired for a polymer where the comonomer is C9 or more, one can refer to T. Sun, P. Brant, R. R. Chance, and W. W. Graessley, Macromolecules, Volume 34, Number 19, 6812-6820, (2001) for protocols on determining standards for those polymers. In the case of syndiotactic polymers, the standard should have a comparable amount of syndiotacticty as measured by Carbon 13 NMR. The viscosity averaged g′ was calculated using the following equation:

$g_{vis}^{\prime} = \frac{\sum{C_{i}\left\lbrack \eta_{i} \right\rbrack}_{b}}{\sum{C_{i}{KM}_{i}^{\alpha}}}$ where C_(i) is the polymer concentration in the slice i in the polymer peak, and [η_(i)]_(b) is the viscosity of the branched polymer in slice i of the polymer peak, and M_(i) is the weight averaged molecular weight in slice i of the polymer peak measured by light scattering, K and α are as defined above.

Peak melting point (Tm) and peak crystallization temperature (Tc) were determined using the following procedure according to ASTM E 794-85. Crystallinity was calculated using heat of fusion determined using ASTM D 3417-99. Differential scanning calorimetric (DSC) data were obtained using a TA Instruments model Q100 machine. Samples weighing approximately 5-10 mg were sealed in aluminum sample pans. The DSC data were recorded by first cooling the sample to −100° C. and then gradually heating it to 200° C. at a rate of 10° C./minute. The sample was kept at 200° C. for 5 minutes before a second cooling-heating cycle was applied. Both the first and second cycle thermal events were recorded. Areas under the melting curves were measured and used to determine the heat of fusion and the degree of crystallinity. The percent crystallinity is calculated using the formula, [area under the curve (Joules/gram)/B (Joules/gram)]*100, where B is the heat of fusion for the homopolymer of the major monomer component. These values for B were obtained from the Polymer Handbook, Fourth Edition, published by John Wiley and Sons, New York 1999. A value of 189 J/g (B) was used as the heat of fusion for 100% crystalline polypropylene. A value of 290 J/g is used for the heat of fusion for 100% crystalline polyethylene. The melting and crystallization temperatures reported here were obtained during the second heating/cooling cycle. For polymers displaying multiple cooling and melting peaks, all the peak crystallization temperatures and peaks melting temperatures were reported. The heat of fusion for each melting peak was calculated individually. Typically, a polymer blend produced in the present process involving a Ziegler-Natta catalyst will show a secondary cooling peak overlapping with the principal peak, which peaks are considered together as a single cooling point. The highest of these peaks is considered the crystallization point.

The glass transition temperature (Tg) was measured by ASTM E 1356 using a TA Instruments model Q100 machine.

Morphology data were obtained using an Atomic Force Microscope (AFM) in tapping phase. All specimens were analyzed within 8 hours after cryofacing to prevent specimen relaxation. During cryofacing, the specimens were cooled to −130° C. and cut with diamond knives in a Reichert cryogenic microtome. They were then stored in a dissector under flowing dry nitrogen gas to warm up to ambient temperatures without condensation being formed. Finally, the faced specimens were mounted in a miniature steel vise for AFM analysis. The AFM measurements were performed in air on a NanoScope Dimension 3000 scanning probe microscope (Digital Instrument) using a rectangular 225-mm Si cantilever. The stiffness of the cantilever was ˜4 N/m with a resonance frequency of ˜70 kHz. The free vibration amplitude was high, in the range of 80 nm to 100 nm, with a RMS setting of 3.8 volts. While the set point ratio was maintained at a value equal to or lower than 0.5, the contact set point was adjusted routinely to ensure repulsive contacts with positive phase shifts. The cantilever was running at or slightly below its resonance frequency.

AFM phase images of all specimens were converted into a TIFF format and processed using PHOTOSHOP (Adobe Systems, Inc.). The image processing tool kit (Reindeer Games, Inc.) was applied for image measurements. Results of image measurements were written into a text file for subsequent data processing using EXCEL (Microsoft) or MATLAB (MathWorks, Inc.) for computing sizes/shapes of dispersed phases, co-continuity factor of co-continuous phases, or nearest-neighbor inter-particle distances.

Transmission Electron Microscopy (TEM) was used to study details of the interface between the ethylene/propylene/diene rubber and the semi-crystalline polypropylene phases. The instrument used was the JEOL 2000FX microscope. A heavy metal staining technique was employed to provide contrast to delineate the details of the sample morphology. Ruthenium tetroxide provides excellent contrast between amorphous and crystalline regions and was used. Lower density and amorphous polymers take up more stain than do higher density and more crystalline components. Thus heavily stained components appear darker in TEM amplitude contrast images whereas less heavily stained materials appear lighter. The TEM analytical method used involved:

-   -   Setting the orientation of the plane of analysis. Typically the         MD-ND (machine direction/normal direction) plane is preferred         for samples that may be oriented in the machine direction.     -   Creating a deformation-free face through the bulk polymer sample         using a cryomicrotome.     -   Staining with ruthenium tetroxide vapor for about 8 hours.     -   Cutting and collecting ultrathin (about 100 nm) sections from         the stained face using an ultramicrotome. The cutting is done         using a diamond knife. Sections are floated onto TEM grids.     -   Loading sections into the TEM for examination at the appropriate         accelerating voltage (typically 160 to 200 kV).     -   Examining the sections to determine level of sampling needed.     -   Acquiring digital images using appropriate vendor software.

The ethylene content of ethylene/propylene copolymers was determined using FTIR according to the following technique. A thin homogeneous film of polymer, pressed at a temperature of about 150° C., was mounted on a Perkin Elmer Spectrum 2000 infrared spectrophotometer. A full spectrum of the sample from 600 cm⁻¹ to 4000 cm⁻¹ was recorded and the area under propylene band at ˜1165 cm⁻¹ and the area of ethylene band at ˜732 cm⁻¹ in the spectrum were calculated. The baseline integration range for the methylene rocking band is nominally from 695 cm⁻¹ to the minimum between 745 and 775 cm⁻¹. For the polypropylene band the baseline and integration range is nominally from 1195 to 1126 cm⁻¹. The ethylene content in wt. % was calculated according to the following equation: ethylene content (wt. %)=72.698−86.495X+13.696X ² where X=AR/(AR+1) and AR is the ratio of the area for the peak at ˜1165 cm⁻¹ to the area of the peak at ˜732 cm⁻¹.

Solvent extraction was used to isolate the different polymer species of the in-reactor polymer blends. The fractionations were carried out in a two-step successive solvent extraction when the polymer blend did not contain any oil: one involving cyclohexane extraction, the other xylene Soxhlet extraction. In the cyclohexane solvent extraction, about 0.3 gram of polymer was placed in about 60 ml of cyclohexane to isolate the uncured and lightly branched elastomeric components of the polymer blend. The mixture was continuously stirred at room temperature for about 48 hours. The soluble fraction (referred as cyclohexane solubles) was separated from the insoluble material (referred as cyclohexane insolubles) using filtration under vacuum. The insoluble material was then subjected to the xylene Soxhlet extraction procedure. In this step, the insoluble material from the room temperature cyclohexane extraction was first extracted for about 24 hours with xylene. The xylene insoluble portion (referred as xylene insolubles) was recovered by filtration and is the extract containing the at least partially cross-linked second polymer. The remaining portion was cooled down to room temperature and retained in a glass container for 24 hours for precipitation. The precipitated component (referred as xylene precipitate) was recovered through filtration and the soluble component (referred as xylene soluble) was recovered by evaporating the xylene solvent. The xylene precipitate fraction is where the thermoplastic crystalline component resides. In the case of blends containing paraffinic oil plasticizer and the like, another Soxhlet solvent extraction step was performed on the sample for 24 hours to isolate the oil from the blend before the cyclohexane extraction and xylene Soxhlet extraction using an azeotrope of acetone and cyclohexane in the ratio 2:1 by volume. The soluble fraction is referred to as azeotrope solubles.

In order to measure the physical properties of the polymer blends, samples were first mixed in a Brabender melt mixer with ˜45 mL mixing head. The polymer was stabilized with antioxidant during mixing in the Brabender. The Brabender was operated at 100 rpm and at temperature of 180° C. Mixing time at temperature was 5-10 minutes, after which the sample was removed from the mixing chamber. The homogenized samples were molded under compression into plaques on a Carver hydraulic press for analysis. About 7 grams of the homogenized polymer were molded between brass platens lined with Teflon™ coated aluminum foil. A 0.033 inch (0.08 cm) thick chase with a square opening 4 inch×4 inch (10.2×10.2 cm) was used to control sample thickness. After one minute of preheat at 170° C. or 180° C., under minimal pressure, the hydraulic load was gradually increased to 10,000 to 15,000 lbs, at which it was held for three minutes. Subsequently the sample and molding plates were cooled for three minutes under 10,000 to 15,000 lbs load between the water-cooled platens of the press. Plaques were allowed to equilibrate at room temperature for a minimum of 24 hours prior to physical property testing.

β relaxation, Loss Modulus (E″) and Storage Modulus (E′) were measured by dynamic mechanical thermal analysis (DMTA). The instrument used was the RSA II, Rheometrics Solid Analyzer II from TA Instruments, New Castle, Del. The instrument was operated in tension mode and used molded rectangular samples. Sample conditions were: 0.1% strain, 1 Hz frequency, and 2° C. per minute heating rate, covering the temperature range from −135° C. to the melting point of the sample. Samples were molded at about 200° C. Typical sample dimensions were 23 mm length×6.4 mm width×thickness between 0.25 mm and 0.7 mm, depending on the sample. Tan δ is the ratio of E″/E′. The output of these DMTA experiments is the storage modulus (E′) and loss modulus (E″). The storage modulus measures the elastic response or the ability of the material to store energy, and the loss modulus measures the viscous response or the ability of the material to dissipate energy. The ratio of E″/E′ (=tan δ) gives a measure of the damping ability of the material. Energy dissipation mechanisms (i.e., relaxation modes) show up as peaks in tan δ, and are associated with a drop in E′ as a function of temperature. The uncertainty associated with reported values of E′ is expected to be on the order of ±10%, due to variability introduced by the molding process.

Shore hardness was determined according to ISO 868.

Stress-strain properties such as ultimate tensile strength, ultimate elongation, and 100% modulus were measured on 2 mm thick compression molded plaques at 23° C. by using an Instron testing machine according to ISO 37.

Compression set test was measured according to ISO 815A.

Tension set was measured according to ISO 2285.

Oil swell (oil gain) was determined after soaking a die-cut sample from compression molded plaque in IRM No.3 fluid for 24 hours at 125° C. according to ASTM D 471.

LCR (Laboratory Capillary Rheometer) viscosity was measured according to ASTM D 3835-02 using a Dynisco Capillary rheometer at 30:1 L/D (length/diameter) ratio, a shear rate of 1200 1/s and a temperature of 204° C. The entrance angle of the laboratory capillary rheometer is 180°, barrel diameter is 9.55 mm. The heat soak time is 6 minutes.

EXAMPLES 1-1 TO 1-6

Examples 1-1 through 1-6 demonstrate a two-stage polymerization reaction with the use of a supported Ziegler-Natta catalyst to produce polypropylene in a slurry process in the first stage, and copolymerizing propylene and ethylene as well as a diene cross-linking agent in a solution process in a second stage in the presence of the homopolymer produced in the first stage. The polymerization was carried out in a 2-liter autoclave reactor equipped with a stirrer, an external water/steam jacket for temperature control, a regulated supply of dry nitrogen, ethylene, propylene, and a septum inlet for introduction of other solvents, catalysts and scavenger solutions. The reactor was first washed using hot toluene and then dried and degassed thoroughly prior to use. All the solvents and monomers were purified by passing through a 1-liter basic alumina column activated at 600° C., followed by a column of molecular sieves activated at 600° C. or Selexsorb CD column prior to transferring into the reactor.

The supported Ziegler-Natta catalyst was comprised of TiCl₄ supported on MgCl₂. Both triethyl aluminum (TEAL) (1 mol. % in hexane) and tri-n-octyl aluminum (TNOA) (25 wt % in hexane) were obtained from Sigma Aldrich. Cyclohexylmethyl dimethoxysilane solution (CMMS) (0.1 mol % in hexane) was used as an external donor and was obtained from Sigma Aldrich.

The catalysts used the second stage were homogeneous metallocene catalysts. [Di(p-triethylsilylphenyl)methylene] (cyclopentadienyl) (3,8-di-t-butylfluorenyl)haflilum dimethyl catalyst (Catalyst B) was produced according to the examples in U.S. Pat. No. 6,528,670 and dimethylsilyl (tetramethylcyclopentadienyl)(cyclododecylamido)titanium dimethyl (Catalyst C) was made according to the examples in U.S. Pat. No. 5,057,475. The dimethyl version was obtained by dimethylation of the dichloride version. Both catalysts were preactivated with dimethyl anilinium tetrakis(heptafluoro-2-naphthyl)borate at a catalyst/activator molar ratio of about 1:1 in toluene to form a stock solution.

1,9-decadiene or VNB was used as the diene cross-linking agent in the second polymerization stage. The 1,9-decadiene and VNB were obtained from Sigma-Aldrich and were purified by first passing through an alumina column activated at high temperature under nitrogen, followed by a molecular sieve activated at high temperature under nitrogen.

In the first stage of polymerization, 2 ml of triethyl aluminum solution (TEAL) (1 mol % in hexane), 20.9 mmole of H2 and 300 ml of propylene were first added into a 2-liter autoclave reactor. The mixture was then immediately stirred and heated rapidly to a desired polymerization temperature. Then a specific amount of Zieglar-Natta catalyst along with 2 ml of cyclohexylmethyl dimethoxysilane solution (CMMS) (0.1 mol % in hexane) was flushed into the reactor with additional propylene. The first stage of polymerization proceeded at the introduction of the catalyst. At the end of the first stage of polymerization, all of the reactor content was kept in the reactor. At the beginning of the second stage, the solvent (such as toluene or hexane) was added into the reactor, followed by the introduction of ethylene. Then, in succession, diene, and additional scavenger (if used), and the preactivated second catalyst were added into the reactor. Thereafter, the reactor was heated to a desired temperature and controlled at a desired pressure by adjusting the ethylene feed pressure. The ethylene was fed on demand to maintain a relatively constant reactor pressure during the second polymerization reaction. The ethylene feed pressure reported in Table 1A was the pressure difference in reactor at the end of the first stage and ethylene feed line pressure during the second stage. The second stage of the polymerization reaction was terminated when desired amount of polymer was produced. Thereafter, the reactor was cooled down and unreacted monomer and solvent (diluent) were vented to the atmosphere. The resulting mixture, containing mostly solvent, polymer and unreacted monomers, was collected in a collection box and first air-dried in a hood to evaporate most of the solvent, and then dried in a vacuum oven at a temperature of about 90° C. for about 12 hours.

For Examples 1-1 and 1-2, at the end of the first stage of polymerization, about 12 ml of air was injected into the reactor with about 100 ml of solvent to partially deactivate the catalyst used in the first stage. The reaction medium was kept under proper mixing for about 8 to 15 minutes to allow good air-catalyst contact prior to the second stage of polymerization. Additional scavenger was used in the second stage of polymerization.

Details of the experimental conditions and the properties of the resultant polymer blends are listed in Tables 1A and 1B below.

TABLE 1A Example # 1-1 1-2 1-3 1-4 1-5 1-6 First stage of polymerization Temperature ° C. 70 70 70 70 70 70 Amount of supported 12 10 9.4 7.5 9 20 catalyst (mg) Propylene (ml) 600 600 500 500 500 500 TEAL (1 mol. %) (ml) 2 2 2 2 2 2 H2 (mmole) 20.9 20.9 20.9 20.9 20.9 0 Reaction time (min) 40 30 30 20 25 60 Second stage of polymerization Temperature (° C.) 75 75 80 100 100 75 Catalyst B B B C C B Amount of catalyst (mg) 4 4.2 3 2 2 4 Propylene (ml) 100 100 0 0 0 100 Ethylene feed pressure 230 230 230 230 230 230 (psi) Cross-link agent Decadiene Decadiene VNB Decadiene VNB Decadiene Amount of cross-link 40 40 50 100 100 100 agent (ml) Toluene (ml) 800 800 800 800 800 800 TNOA (25 wt%) (ml) 12 12 0 0 0 0 Reaction time (min) 27 40 10 10 10 10 Yield (g) 158 51.1 168 86 149 90.5 Tc in a primary cooling 107.6 110.8 102.2 109.7 108.6 108.1 peak (° C.) Tm in a primary melting 165.6 164.5 168.7 166.1 166.4 165.8 peak (° C.) Heat of fusion in a 18.2 9.4 24.7 30.8 21.4 19.3 primary melting peak (J/g) Tg (° C.) −49.4 −52.9 −47.4 −53.1 −54.1 −50.3 Tc in a secondary cooling 89.0 peak (° C.) Tm in a secondary 119.3 118.8 122.5 119.0 117.5 120.1 melting peak (° C.) Heat of fusion of a 20.8 19.5 14.4 2.7 3.7 9.7 secondary melting peak (J/g) Ethylene content (wt %) 48.7 52.0

TABLE 1B Solvent extraction data for polymers in Examples 1-1 to 1-6 Example # 1-1 1-2 1-3 1-4 1-5 1-6 Xylene precipitate (wt %) 82.9 83.1 ′73.7 52.6 44.3 79.0 Xylene insolubles (wt %) 9.8 1.5 0.5 1.7 2.7 11.3 Xylene solubles (wt %) 4.0 3.1 16.3 14.5 7.5 Cyclohexane solubles (wt %) 3.4 12.4 9.6 31.1 45.5 2.0 Degree of cross-link (%) 57.1 8.6 1.7 3.7 4.9 53.9

Degree of cross-link is defined as:

${{Degree}\mspace{14mu}{of}\mspace{14mu}{cross}\text{-}{link}} = {\frac{{Percent}\mspace{14mu}{of}\mspace{14mu}{xylene}\mspace{14mu}{insoluble}}{100 - {{percent}\mspace{14mu}{of}\mspace{14mu}{xylene}\mspace{14mu}{precipitate}}} \times 100}$

The degree of cross-link is also referred as to the percent of fraction insoluble in xylene of the second polymer.

All of the polymers produced in Examples 1-1 to 1-6 show dual melting peaks and a broad overlapping cooling peak in the second heating/cooling cycle on the DSC traces. It is believed that the presence of the second peak is due to the polymer derived from the Ziegler-Natta catalyst in the second stage of polymerization.

The Tg values shown in Table 1A above refer to the elastomer component in the reactor-produced blend examples. The values provide an indication of the amorphous nature of the elastomer component. The Tg of the polypropylene component—located primarily in the xylene precipitate fraction—is generally about 0° C., typical for semi-crystalline propylene homopolymers

The polymer blends produced in Examples 1-1 to 1-6 were melt mixed in a Brabender mixer and molded under compression into plaques, and tested for thermoplastic elastomer applications. The performance data obtained using the procedure described above are listed in Table 2 and 3.

Polymer blends produced in Examples 1-1 through 1-6 were also post reactor cured by dynamic vulcanization. The vulcanization was effected by conventional techniques within a Brabender mixer along with the other added ingredients listed in Tables 2 and 3. Silicon hydride DC 25804 (1.97%) was obtained from Dow Coming. The silicon hydride was a polysiloxane with silicon hydride functionality. SP1045 is a phenolic resin obtained from Schenectady International (Schenectady, N.Y.). Platinum catalyst mixture (PC085) (2.63%) was obtained from United Chemical Technologies Inc. The catalyst mixture included 0.0055 parts by weight platinum catalyst and 2.49 parts by weight mineral oil. Zinc oxide was obtained from Zinc Corporation of America. Paraffinic oil Paralux 6001R was obtained from Chevron Oil Corporation. Stannous chloride anhydrous was obtained from Mason Corp., U.S. Route 41, Schererville, Ind. PP is homopolypropylene obtained from Equistar under trade name of Equistar F008F. The performance data obtained using the procedure described above are listed in Table 2 and 3. The improvements of dynamic cured polymer blends were noticed by the enhancement in elastomeric properties such as compression set and weight gain.

TABLE 2 Polymer 1-1 1-2 1-6 1-1 1-2 1-6 Polymer (wt. %) 100 100 100 42.64 41.75 44.54 Paralux 6001R (wt. %) 0 0 0 38.38 37.58 40.09 PP (wt. %) 0 0 0 12.79 14.61 8.91 SiH (DC 2-5084) (wt. %) 0 0 0 1.28 1.25 1.34 Pt (PC085) (wt. %) 0 0 0 3.41 3.34 3.56 Zinc oxide (wt. %) 0 0 0 0.85 0.84 0.89 Stannous chloride (wt. %) 0 0 0 0.21 0.21 0.22 Hardness (Shore A) 92 80 87 80 77 78 Ultimate tensile strength 19.63 16.83 18.23 12.64 10.8 11.58 (MPa) Ultimate elongation (%) 526 563 480 672 640 522 100% modulus (MPa) 8.37 4.17 9.2 4.66 3.89 4.99 LCR Viscosity at 1200 l/s 372 310 405 78 85 85 (Pa-s) Tension Set (%) 28 17 27 20 16 16 Compression set at 62 78 65 37 33 36 70° C./22 hrs (%) Weight Gain @121° C./24 hrs 423 511 143 156 120 (%)

TABLE 3 Polymer 1-3 1-4 1-5 1-3 1-4 1-5 Polymer (wt. %) 100 100 100 44.54 42.64 40.90 Paralux 6001R (wt. %) 0 0 0 40.09 38.38 36.81 PP (wt. %) 0 0 0 8.91 12.79 16.36 SiH (DC 2-5084) (wt. %) 0 0 0 1.34 1.28 1.23 Pt (PC085) (wt. %) 0 0 0 3.56 3.41 3.27 Zinc oxide (wt. %) 0 0 0 0.89 0.85 0.82 Stannous chloride (wt. %) 0 0 0 0.22 0.21 0.20 Hardness (Shore A) 90 89 72 72 76 77 Ultimate tensile strength 12.35 6.77 3.22 4.19 5.21 7.21 (MPa) Ultimate elongation (%) 590 198 217 359 302 238 100% modulus (MPa) 7.4 6.63 3.19 3.39 4.12 4.89 LCR Viscosity at 1200 l/s 313 258 296 60 95 87 (Pa-s) Tension Set (%) 40 62 50 40 31 16 Compression set at 87 90 95 79 60 38 70° C./22 hrs (%) Weight Gain @121° C./24 hrs 382 284 395 83 155 105 (%)

The morphology of the polymer blend produced in Example 1-1 was examined using AFM according to the procedure described above and the result is shown in FIG. 1. It was observed that the rubber was in the discrete particle phase embedded in polypropylene matrix. The inclusion of polypropylene inside the discrete particles was also observed.

In another embodiment this invention relates to:

-   1. A process for producing a polymer blend comprising a     thermoplastic first polymer having a crystallinity of at least 30%     and a second polymer having a crystallinity of less than 20% and     being at least partially cross-linked, the process comprising:     -   (a) polymerizing at least one first monomer in a first slurry         phase reaction zone in the presence of a supported first         catalyst under conditions to produce said thermoplastic first         polymer, said first catalyst comprising a Ziegler-Natta         catalyst; and     -   (b) contacting at least part of said first polymer with at least         one second monomer different from said first monomer and at         least one polyene in a second solution phase reaction zone under         conditions sufficient to polymerize said second monomer to         produce and at least partially cross-link said second polymer         such that said second polymer comprises at least a fraction         which is insoluble in xylene. -   2. The process of paragraph 1 wherein the second catalyst comprises     a metallocene catalyst. -   3. The process of paragraph 1 or 2 wherein said thermoplastic first     polymer is a homopolymer of propylene or a copolymer of propylene     with less than 10 wt % of at least one comonomer. -   4. The process of any of paragraphs 1 to 3 wherein said at least one     comonomer comprises ethylene or a C4 to C12 olefin. -   5. The process of any of paragraphs 1 to 4 wherein said second     monomer comprises ethylene. -   6. The process of any of paragraphs 1 to 5 wherein said second     polymer is a copolymer of propylene with from about 8 wt % to about     70 wt % of said at least one second monomer comprising ethylene. -   7. The process of any of paragraphs 1 to 6 wherein said polymer     blend comprises a heterogeneous blend in which said first polymer     comprises a continuous phase of the blend and said second polymer is     in the form of particles dispersed in said continuous phase. -   8. The process of any of paragraphs 1 to 7 wherein said polymer     blend comprises a homogeneous blend. -   9. The process of any of paragraphs 1 to 8 wherein said polyene has     at least two polymerizable unsaturated groups -   10. The process of any of paragraphs 1 to 9 wherein said polyene is     a diene. -   11. The process of any of paragraphs 1 to 10 wherein said fraction     insoluble in xylene comprises at least 4% by weight of said second     phase. -   12. A process for producing a polymer blend comprising a first phase     comprising a thermoplastic first polymer comprising units derived     from propylene and a second elastomeric phase comprising an at least     partially cross-linked second polymer comprising units derived from     ethylene, propylene and at least one polyene, the process     comprising:     -   (a) polymerizing at least one first monomer comprising propylene         in a first slurry phase reaction zone in the presence of a         supported first catalyst under conditions to produce said         thermoplastic first polymer, said first catalyst comprising a         Ziegler-Natta catalyst; and     -   (b) contacting at least part of said first polymer with at least         one second monomer comprising ethylene and at least one polyene         in a second solution phase reaction zone in the presence of a         second catalyst under conditions to produce and at least         partially cross-link said second polymer such that said second         polymer comprises at least a fraction which is insoluble in         xylene. -   13. The process of paragraph 12 wherein the second catalyst     comprises a metallocene catalyst. -   14. The process of paragraph 12 or 13 wherein said thermoplastic     first polymer is a homopolymer of propylene or a copolymer of     propylene with less than 10 wt % of at least one comonomer. -   15. The process of any of paragraphs 12 to 14 wherein said at least     one comonomer comprises ethylene or a C4 to C12 olefin. -   16. The process of any of paragraphs 12 to 15 wherein said second     polymer is a copolymer of propylene with from about 8 wt % to about     70 wt % of said at least one second monomer comprising ethylene. -   17. The process of any of paragraphs 12 to 16 wherein said polymer     blend comprises a heterogeneous blend in which said first polymer     comprises a continuous phase of the blend and said second polymer is     in the form of particles dispersed in said continuous phase. -   18. The process of any of paragraphs 12 to 17 wherein said polymer     blend comprises a homogeneous blend. -   19. The process of any of paragraphs 12 to 18 wherein said polyene     has at least two polymerizable unsaturated groups -   20. The process of any of paragraphs 12 to 19 wherein said polyene     is a diene. -   21. The process of any of paragraphs 12 to 20 wherein said fraction     insoluble in xylene comprises at least 4% by weight of said second     phase. -   22. A process for producing a polymer blend comprising a first phase     comprising a thermoplastic first polymer comprising units derived     from propylene and a second elastomeric phase comprising an at least     partially cross-linked second polymer comprising units derived from     ethylene, propylene and at least one polyene, the process     comprising:     -   (a) polymerizing at least one first monomer comprising propylene         in a first slurry phase reaction zone in the presence of a         supported Ziegler-Natta catalyst under conditions to produce         said thermoplastic first polymer; and     -   (b) contacting at least part of said first polymer with at least         one second monomer comprising ethylene and at least one polyene         in a second solution phase reaction zone in the presence of a         metallocene catalyst under conditions to produce and at least         partially cross-link said second polymer such that said second         polymer comprises at least a fraction which is insoluble in         xylene. -   23. The process of paragraph 22 wherein said thermoplastic first     polymer is a homopolymer of propylene or a copolymer of propylene     with less than 10 wt % of at least one comonomer. -   24. The process of paragraph 23 wherein said at least one comonomer     comprises ethylene or a C4 to C12 olefin. -   25. The process of any of paragraphs 22 to 24 wherein said second     polymer is a copolymer of propylene with from about 8 wt % to about     70 wt % of said at least one second monomer comprising ethylene. -   26. The process of any of paragraphs 22 to 25 wherein said polymer     blend comprises a heterogeneous blend in which said first polymer     comprises a continuous phase of the blend and said second polymer is     in the form of particles dispersed in said continuous phase. -   27. The process of any of paragraphs 22 to 26 wherein said polymer     blend comprises a homogeneous blend. -   28. The process of any of paragraphs 22 to 27 wherein said polyene     has at least two polymerizable unsaturated groups -   29. The process of any of paragraphs 22 to 28 wherein said polyene     is a diene. -   30. The process of any of paragraphs 22 to 29 wherein said fraction     insoluble in xylene comprises at least 4% by weight of said second     phase.

All documents described herein are incorporated by reference herein, including any priority documents and/or testing procedures to the extent they are not inconsistent with this text. While there have been described what are presently believed to be the preferred embodiments of the present invention, those skilled in the art will realize that other and further embodiments can be made without departing from the spirit of the invention, and is intended to include all such further modifications and changes as come within the true scope of the claims set forth herein. 

1. A process for producing a polymer blend comprising a thermoplastic first polymer having a crystallinity of at least 30% and a second polymer having a crystallinity of less than 20% and being at least partially cross-linked, the process comprising: (a) polymerizing at least one first monomer in a first slurry phase reaction zone in the presence of a supported first catalyst under conditions to produce said thermoplastic first polymer, said first catalyst comprising a Ziegler-Natta catalyst; and (b) polymerizing at least one second monomer different from said first monomer and at least one polyene in a second solution phase reaction zone in the presence of said thermoplastic first polymer under conditions sufficient to produce an at least partially cross-linked said second polymer having at least a fraction which is insoluble in xylene in the form of finely dispersed particles embedded within the thermoplastic first polymer.
 2. The process of claim 1 wherein the second catalyst comprises a metallocene catalyst.
 3. The process of claim 1 wherein said thermoplastic first polymer is a homopolymer of propylene or a copolymer of propylene with less than 10 wt % of at least one comonomer.
 4. The process of claim 3 wherein said at least one comonomer comprises ethylene or a C₄ to C₁₂ olefin.
 5. The process of claim 1 wherein said second monomer comprises ethylene.
 6. The process of claim 1 wherein said second polymer is a copolymer of propylene with from about 8 wt % to about 70 wt % of said at least one second monomer comprising ethylene.
 7. The process of claim 1 wherein said polymer blend comprises a heterogeneous blend in which said first polymer comprises a continuous phase of the blend and said second polymer is in the form of particles dispersed in said continuous phase.
 8. The process of claim 1 wherein said polymer blend comprises a homogeneous blend.
 9. The process of claim 1 wherein said polyene has at least two polymerizable unsaturated groups.
 10. The process of claim 1 wherein said polyene is a diene.
 11. The process of claim 1 wherein said fraction insoluble in xylene comprises at least 4% by weight of said second phase.
 12. A process for producing a polymer blend comprising a first phase comprising a thermoplastic first polymer comprising units derived from propylene and a second elastomeric phase comprising an at least partially cross-linked second polymer comprising units derived from ethylene, propylene and at least one polyene, the process comprising: (a) polymerizing at least one first monomer comprising propylene in a first slurry phase reaction zone in the presence of a supported first catalyst under conditions to produce said thermoplastic first polymer, said first catalyst comprising a Ziegler-Natta catalyst; and (b) polymerizing at least part of said first polymer with at least one second monomer comprising ethylene and at least one polyene in a second solution phase reaction zone in the presence of said thermoplastic first polymer and a second catalyst under conditions to produce an at least partially cross-linked said second polymer comprises at least a fraction which is insoluble in xylene in the form of finely dispersed particles embedded within the thermoplastic first polymer.
 13. The process of claim 12 wherein the second catalyst comprises a metallocene catalyst.
 14. The process of claim 12 wherein said thermoplastic first polymer is a homopolymer of propylene or a copolymer of propylene with less than 10 wt % of at least one comonomer.
 15. The process of claim 14 wherein said at least one comonomer comprises ethylene or a C₄ to C₁₂ olefin.
 16. The process of claim 12 wherein said second polymer is a copolymer of propylene with from about 8 wt % to about 70 wt % of said at least one second monomer comprising ethylene.
 17. The process of claim 12 wherein said polymer blend comprises a heterogeneous blend in which said first polymer comprises a continuous phase of the blend and said second polymer is in the form of particles dispersed in said continuous phase.
 18. The process of claim 12 wherein said polymer blend comprises a homogeneous blend.
 19. The process of claim 12 wherein said polyene has at least two polymerizable unsaturated groups.
 20. The process of claim 12 wherein said polyene is a diene.
 21. The process of claim 12 wherein said fraction insoluble in xylene comprises at least 4% by weight of said second phase.
 22. A process for producing a polymer blend comprising a first phase comprising a thermoplastic first polymer comprising units derived from propylene and a second elastomeric phase comprising an at least partially cross-linked second polymer comprising units derived from ethylene, propylene and at least one polyene, the process comprising: (a) polymerizing at least one first monomer comprising propylene in a first slurry phase reaction zone in the presence of a supported Ziegler-Natta catalyst under conditions to produce said thermoplastic first polymer; and (b) polymerizing at least part of said first polymer with at least one second monomer comprising ethylene and at least one polyene in a second solution phase reaction zone in the presence of said thermoplastic first polymer and a metallocene catalyst under conditions to produce an at least partially cross-linked said second polymer having at least a fraction which is insoluble in xylene in the form of finely dispersed particles embedded within the thermoplastic first polymer.
 23. The process of claim 22 wherein said thermoplastic first polymer is a homopolymer of propylene or a copolymer of propylene with less than 10 wt % of at least one comonomer.
 24. The process of claim 23 wherein said at least one comonomer comprises ethylene or a C₄ to C₁₂ olefin.
 25. The process of claim 22 wherein said second polymer is a copolymer of propylene with from about 8 wt % to about 70 wt % of said at least one second monomer comprising ethylene.
 26. The process of claim 22 wherein said polymer blend comprises a heterogeneous blend in which said first polymer comprises a continuous phase of the blend and said second polymer is in the form of particles dispersed in said continuous phase.
 27. The process of claim 22 wherein said polymer blend comprises a homogeneous blend.
 28. The process of claim 22 wherein said polyene has at least two polymerizable unsaturated groups.
 29. The process of claim 22 wherein said polyene is a diene.
 30. The process of claim 22 wherein said fraction insoluble in xylene comprises at least 4% by weight of said second phase. 